Kuga Mk1 Workshop Manual PDF

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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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FOREWORD
To the best of our knowledge, the illustrations, technical information, data and descriptions in
this issue were correct at the time of going to print. The right to change prices, specifications,
equipment and maintenance instructions at any time without notice is reserved as part of FORD
policy of continuous development and improvement for the benefit of our customers.
No part of this publication may be reproduced, stored in a data processing system or transmitted
in any form, electronic, mechanical, photocopy, recording, translation or by any other means
without prior permission of Ford Motor Company. No liability can be accepted for any
inaccuracies in this publication, although every possible care has been taken to make it as
complete and accurate as possible.
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General Information
100-00-1
SECTION 100-00 General Information

VEHICLE APPLICATION: 2008.50 Kuga
CONTENTS
PAGE
PAGE 1 OF 2
DESCRIPTION AND OPERATION

About This Manual..............................................................................................................
Introduction.........................................................................................................................
How to use Repair Procedures...........................................................................................
Global Authoring Standards (GAS) Repair Procedures..................................................
How to use Diagnosis and Testing procedures..................................................................
Symbols Glossary...............................................................................................................
Steering System Health and Safety Precautions................................................................
Health and Safety Precautions...........................................................................................
Introduction.........................................................................................................................
Acids and Alkalis................................................................................................................
Air Bags..............................................................................................................................
Air Conditioning Refrigerant...............................................................................................
Adhesives and Sealers.......................................................................................................
Antifreeze...........................................................................................................................
Asbestos.............................................................................................................................
Battery Acids......................................................................................................................
Brake and Clutch Linings and Pads...................................................................................
Brake Fluids (Polyalkylene Glycols)...................................................................................
Brazing...............................................................................................................................
Chemical Materials.............................................................................................................
Chlorofluorocarbons (CFC)................................................................................................
Clutch Fluids.......................................................................................................................
Clutch Linings and Pads.....................................................................................................
Corrosion Protection Materials...........................................................................................
Cutting................................................................................................................................
Dewaxing............................................................................................................................
Dusts..................................................................................................................................
Electric Shock.....................................................................................................................
Engine Oils.........................................................................................................................
Exhaust Fumes...................................................................................................................
Fibre Insulation...................................................................................................................
Fire.....................................................................................................................................
First Aid..............................................................................................................................
Fluoroelastomer..................................................................................................................
Foams - Polyurethane........................................................................................................
Freon..................................................................................................................................
Fuels...................................................................................................................................
Gas Cylinders.....................................................................................................................
Gases.................................................................................................................................
Gaskets (Fluoroelastomer).................................................................................................
General Workshop Tools and Equipment...........................................................................
High Pressure Air, Lubrication and Oil Test Equipment......................................................
Halon..................................................................................................................................
Legal Aspects.....................................................................................................................
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Lubricants and Greases.....................................................................................................

Transmission Fluids............................................................................................................
Noise..................................................................................................................................
Noise Insulation Materials..................................................................................................
O-Rings (Fluoroelastomer).................................................................................................
Paints..................................................................................................................................
Pressurized Equipment......................................................................................................
Solder.................................................................................................................................
Solvents..............................................................................................................................
Sound Insulation.................................................................................................................
Suspended Loads...............................................................................................................
Transmission Brake Bands.................................................................................................
Underseal...........................................................................................................................
Viton....................................................................................................................................
Welding...............................................................................................................................
Warning Symbols on Vehicles............................................................................................
White Spirit.........................................................................................................................
Standard Workshop Practices............................................................................................
Vehicle in Workshop...........................................................................................................
Towing the Vehicle..............................................................................................................
Connecting a Slave Battery Using Jumper Cables............................................................
Component Cleaning..........................................................................................................
Calibration of Essential Measuring Equipment...................................................................
Solvents, Sealants and Adhesives.....................................................................................
Introduction.........................................................................................................................
Road/Roller Testing............................................................................................................
Pre-Test Checks.................................................................................................................
Starting the Engine.............................................................................................................
Road or Roller Testing........................................................................................................
Brake Testing......................................................................................................................
Air Conditioning (A/C) System Health and Safety Precautions..........................................
Battery and Battery Charging Health and Safety Precautions............................................
Brake System Health and Safety Precautions....................................................................
Engine Cooling System Health and Safety Precautions.....................................................
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions...........................
Supplemental Restraint System (SRS) Health and Safety Precautions.............................
Window Glass Health and Safety Precautions...................................................................
Body Repair Health and Safety and General Precautions.................................................
General...............................................................................................................................
Personal protection.............................................................................................................
Protection of the vehicle.....................................................................................................
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About This Manual

Introduction
Vehicle LH and RH definition
This manual covers diagnosis and testing and

repair procedures.
1
It is structured into groups and sections, with

specific system sections grouped together under
their relevant group.
A group covers a specific portion of the vehicle.

The manual is divided into five groups, General
Information, Chassis, Powertrain, Electrical and
Body and Paint. The number of the group is the
first number of a section number.
Within Etis, the navigation tree will list the groups.
After selecting a group the navigation tree will then
list the sections within that group. Each section has
a contents list detailing Specifications, Description
and Operation, Diagnosis and Testing, General
Procedures, Disassembly and Assembly, Removal
and Installation.
References to LH (left-hand) and RH

(right-hand)
All LH and RH references to the vehicle are taken
from a position sitting in the driver seat looking
forward.
E126780
Item
Description
LH
RH
All LH and RH references to the engine are taken

from a position at the flywheel looking towards the
crankshaft pulley.
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100-00-4

safety or vehicle integrity is not compromised by
the choice of method, tools or components.
Powertrain LH and RH definition
Warnings, Cautions and Notes in This

Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate

that failure to follow a procedure correctly
may result in damage to the vehicle or
equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
Generic warnings or cautions are in their relevant
description and operation procedure within section
100-00. If the generic warnings or cautions are
required for a procedure, there will be a referral to
the appropriate description and operation
procedure.
3
E126781
Item
If a warning, caution or note only applies to one

step, it is placed at the beginning of the specific
step.
Description
front
right hand
rear
left hand
How to use Repair Procedures

This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. It provides general descriptions for
accomplishing repair work with tested and effective
techniques.
Important Safety Instructions

Appropriate service methods and correct repair
procedures are essential for the safe and reliable
operation of all vehicles as well as the personal
safety of the individual carrying out the work.
Global Authoring Standards (GAS) Repair

Procedures
NOTE: GAS style procedures can be identified by
steps that have no accompanying step text and
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a
sequence of color illustrations to indicate the order
to be followed when removing/disassembling or
installing/assembling a component.
Many of the GAS procedures will have the
installation information within the removal steps.
These procedures will have the following note at
the beginning of the procedure:
NOTE: Removal steps in this procedure may
contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the

reuse of fasteners and seals and gaskets.
Anyone who departs from the instructions provided

in this manual must first establish that personal
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Types of self-locking nuts and bolts
NOTE: There are more types of self-locking fasteners available than shown in following illustration.
E126782
Item
Description
Completely coated self-locking bolt
Partially coated self-locking bolt
Self-locking bolt with a locking washer
Self-locking nut with a plastic locking insert
Self-locking nut with thread deformation

(3 identations)
Self-locking nut with thread deformation

(to oval shape)
Self-locking nut with integrated locking ring
All types of seals and gaskets must be

discarded and new seals and gaskets installed
unless otherwise stated within the procedure.
Nuts and bolts with a chemical coating for
locking and/or sealing and/or antiseize must be
discarded unless the procedure advises to
reapply the coating with a specified material.
Nuts and bolts with a mechanical locking such

as thread inserts, thread deformation or locking
washers must be discarded and new nuts and
bolts installed unless otherwise stated within
the procedure.
Torque to yield bolts must be discarded and
new torque to yield bolts installed unless
otherwise stated within the procedure,
recognizable by a tightening torque with more
than one stage together with a torque angle.
Reuse of exterior trim parts
All type of glued exterior trim parts or parts

fastened with adhesive tape must be discarded
and new parts installed unless otherwise stated
within the procedure.
Specification data
Specification procedures will only contain technical

data that is not already part of a repair procedure.
Sequence of tasks
If components must be removed or installed in a

specific sequence, the sequence will be identified
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numerically in a graphic and the corresponding text
will be numbered accordingly.
Item
3
Brown - Components that need to be

removed prior to or installed after the
target/primary.
Yellow - Components to be set aside only,

that remains in the vehicle. Also
highlighted areas to inspect or adjust.
Magenta - Electrical connectors and

fasteners such as nuts, bolts, clamps, or
clips to be: detached, attached, loosened,
moved, removed or installed.
Pale Blue - Special tool(s), general

equipment, or common tools (used in an
uncommon way).
Special Tools, Equipment, Materials and Torque

Figures
Special tools will be shown with the tool numbers

in the illustration. The special tool numbers, general
equipment, materials and torque figures used for
the procedure step will be shown in the text
column.
GAS Graphics
NOTE: Colors used in the graphic are as follows:
Description
One illustration may have multiple steps assigned

to it.
Numbered pointers are used to indicate the number
of electrical connectors and fasteners such as nuts,
bolts, clamps and clips.
Items in the illustration can be transparent or use

cutouts to show hidden details.
x2
E141161
Item
Description
Blue - Target or primary component to be

removed/installed (or
disassembled/assembled).
Green - Components that need to be

removed prior to or installed after the
target/primary.
E132042
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E125925
x2
1
3
4
E132377
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E133487
E132233
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100-00-9
303-1288
x1
x2
303-1288
E92595
2
GAS Service Action Icon
x1
4
E83478
Symbols are used inside the graphics and in the

text area to enhance the information display. The
following paragraphs describe the various types
and categories of symbols.
For additional information, refer to: Symbols
Glossary (100-00 General Information,
Description and Operation).
Prohibition symbols advise on prohibited actions
to either avoid damage or health and safety related
risks. These symbols are:
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100-00-10
E85026
Health and Safety symbols recommend the use of

particular protection equipment to avoid or at least
reduce the risk or severity of possible injuries.
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100-00-11
1
2
3
E85027
Warning symbols are used to indicate potential

risks resulting from a certain component or area.
E85028
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Instruction symbols are used to apply sealer,
lubricant, weight, tape or cleaning detergent to a
component.
E84834
Location symbols are used to show the location of

a component or system within the vehicle.
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E84835
Gearshift lever or selector lever position symbols

are used to show which gearshift lever or selector
lever position is to be set.
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General Information
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308-640
E84836
Pointer symbols are used to draw attention to

components and give special instructions such as
a required sequence or number of components.
The number of components is reflected by the
value inside the luty arrow. A sequence number is
2008.50 Kuga 8/2011
located inside the circle. Numbers inside circles

are also used to allocate special information such
as tightening torques or chemicals to a particular
component.
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3
2
2
1
TO BE UPDATED
1
x12
E84837
Movement arrows are used to show three

dimensional or rotational movements. These
movements can include specific values inside the

symbol if required.
E84838
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Standard tool symbols recommend the use of
certain standard tools. These tools can include
dimension values if required.
E84839
The following graphic illustrates a set of symbols

that are used to provide detailed information on
where to apply a material.
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100-00-22

Item
Description
Item
Description
Steering wheel in straight ahead position
Steering column lock locked
Turn the steering wheel to the 90 right

position
Steering column lock unlocked
Turn the steering wheel to the left-hand

end position
Turn the steering wheel to the 90 left

position
Turn the steering wheel to the right-hand

end position
10
11
E88971
Item
Description
Item
Description
3, 4, 5-door body style
Sports utility vehicle body style
Wagon body style
Coupe body style
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100-00-17
E84840
Measurement symbols provide detailed information

on where to carry out a specific measurement.
These symbols can include specific values if

required.
E84841
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How to use Diagnosis and Testing
procedures
Inspection and Verification
Visual Inspection Charts, Symptom Charts and

other information charts (such as diagnostic
routines) or supplement test procedures with
technical specifications will navigate the user to a
specific test procedure.
Symptom Chart
The symptom chart indicates symptoms, sources

and actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used

to identify the source of a concern in a logical,
step-by-step manner. Pinpoint tests have two
columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
The boxed numbers indicate the order in which the
described action is to be carried out.
Component Tests
A component test is used when a component is

tested in multiple pinpoint tests, or if a procedure
is too complicated to be formatted within a single
page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be

carried out in a test step.
A representative tester graphic is used for
voltmeters and ohmmeters.
If multiple measurements are made in a single
graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple
measurements, at which point dashed lines are
used.
Breakout box type testers are represented by a
double circle test pin. Test pins are labeled with
the pin number.
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100-00-23

Item
Description
Item
Description
Convertible body style
10
Right-hand drive (RHD) vehicle
Van body style
11
Left-hand drive (LHD) vehicle
3, 4, 5-door body style - Top View
Wagon body style - Top View
Underview
Gearshift lever and selector lever position symbols
Gearshift lever and selector lever position symbols

are used to show the lever position that is required
to be selected to carry out a procedure step.
10
E88972
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General Information
100-00-19
Symbols Glossary
Symbols are used inside the graphics and in the
text area to enhance the information display.
Movement Symbols
Movement symbols provide detailed information

to a required component movement. These
component movements can be rotational or 1-3
dimensional movements.
E88969
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100-00-20

Item
Description
Item
Minor component movement

clockwise/counterclockwise
Major component movement

clockwise/counterclockwise
Component movement to the

left/right/up/down
Component movement towards/away
3 dimensional component movement
Description
2 dimensional component movement
3 dimensional component rotation
3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further

information on the direction or angle of component
turns.
E88970
2008.50 Kuga 8/2011
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100-00-24
100-00-24

Item
Description
Item
Description
Set the selector lever to the park (P)

position
Set the selector lever with manual shift

pattern to the shift down (-) position
Set the selector lever to the reverse ( R )

position

pattern to the shift up (+) position
Set the selector lever to the neutral (N)

position
Set the gearshift lever to the neutral (N)

position
Set the selector lever to the drive (D)

position
10
Further gearshift lever positions that may

appear in illustrations

pattern to the park (D) position
Screwdriver symbols

pattern to the manual (M) position
The screwdriver symbols are used to show which

screwdriver bit is recommended to carry out a
procedure step.
2008.50 Kuga 8/2011
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General Information
100-00-21
100-00-21

Item
Description
Item
Description
Turn the component clockwise through

45
Turn the component counterclockwise

through 180

through 45
Turn the component clockwise through 2

complete turns

90

through 2 complete turns

through 90
Steering Wheel Symbols

180
Steering wheel symbols are used to provide further

information to a required steering wheel position
or steering column lock status.
E123751
2008.50 Kuga 8/2011
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100-00-25
100-00-25
E88973
Item
Description
Item
Description
Screwdriver
Hexagonal screwdriver
Cross bladed screwdriver
TORX screwdriver
Flat bladed screwdriver
Pliers symbols
The pliers symbols are used to show which pliers

is recommended to carry out a procedure step.
2008.50 Kuga 8/2011
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100-00-26
100-00-26
E88974
Item
Description
Item
Description
Combination pliers
Securing ring pliers - inner
Side cutter pliers
Securing ring pliers - outer
2008.50 Kuga 8/2011
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100-00-27
100-00-27

Item
Description
Hose clamp pliers
Locking pliers
Long nose pliers
Drill symbols
The drill symbols are used to show which type and

size of drill bit is recommended to carry out a
procedure step.
M6
M6
E88975
Item
Description
Item
Description
Drill bit with a specified diameter
Scraper for circular holes
Hole saw with a specified diameter
Scraper for straight edges
Stepped drill bit with a specified diameter
Cutting tool symbols
Tap with a specified diameter
Die with a specified diameter
The cutting tool symbols are used to show which

type of cutting tool is recommended to carry out a
procedure step.
2008.50 Kuga 8/2011
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100-00-28
100-00-28
11
12
5mm
10
5mm
E88976
Item
Description
Cutting knife
Air body saw
Scissors
Grinder
Jig saw
Plasma cutter
Sanding Paper
2008.50 Kuga 8/2011
Item
Description
Drill through the shown number of body

panel layers with a specified diameter
Drill through the shown number of body

panel layers with a suitable diameter
10
Drill through 1 body panel layer with a

specified diameter
11
Drill through 1 body panel layer with a

suitable diameter
12
Wire brush
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General Information
100-00-29
100-00-29

Apply Chemical or load symbols
The apply chemical or load symbols are used to
show where to apply which type of chemical or

load to carry out a procedure step.
10mm
12
10
13
14
18
E88977
2008.50 Kuga 8/2011
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100-00-30
100-00-30

Item
Description
Item
Description
Apply the substance from the specified

tube
12
Apply a broken bead from the specified

tube
Apply the substance from the specified

cartridge
13
Apply the specified chemical from a spray

can
Apply the specified chemical with a brush
14
Apply the specified load to the specified

component
Apply the specified lubricant to the

specified component
15
Apply a bead with a specific diameter from

the specified tube
Apply spot welds to the specified

component
16
Apply a bead with a specific diameter from

the specified cartridge
Apply a continuous weld to the specified

component
17
Handle the fluid using a syringe
Apply the specified chemical with a roller
18
Apply hot glue to the specified component
Extract the specified amount of fluid using

a syringe
Apply the specified amount of fluid from

the fluid can
10
Apply fluid from the fluid can
11
Clean the specified component with the

specified material
5
6
2008.50 Kuga 8/2011
Measurement symbols
The measurement symbols are used to show

where to measure which type of measurement to
carry out a procedure step.
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100-00-36
100-00-36

Item
Description
Item
Description
Self contained breathing apparatus
12
Fully apply the parking brake lever
General prohibition used in combination

with another symbol
13
Fully release the parking brake lever
14
Do not use power tools
Do not dispose of batteries into the waste

bin
Visual check
15
Visual check using a mirror
Noise check
16
Area/component must be dry
Dispose the specified component
10
Replaced by item 9 (Dispose the specified

component)
11
Set the engine speed to the specified

value
2008.50 Kuga 8/2011
Mandatory Protective equipment - Health and safety

symbols
The protective equipment symbols advise to use

a mandatory protective equipment to avoid or at
least reduce possible health and safety risks.
G955392en

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General Information
100-00-31
100-00-31
C
9
80
100
100
10
11
80
12
80
mm
10.65 +- 0.25
mm
0.02
mm
0.02
E88978
2008.50 Kuga 8/2011
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100-00-32
100-00-32

Item
Description
Item
Description
Measure the current using a digital

multimeter
10
The specified task requires the specified

maximum temperature not to be exceeded
Measure the voltage using a digital

multimeter
11

temperature range
Measure the resistance using a digital

multimeter
12

temperature
Measure the length/distance
13
Check that the specified pressure is

available using a suitable pressure gauge
Measure and check for the specified value

using a dial indicator gauge
14
Measure the pressure at the specified port

using a suitable pressure gauge
Measure and check for the specified MAX

value using a dial indicator gauge
15
Measure and check for the specified MIN

value using a dial indicator gauge
6
7
Measure the time using a suitable

stopwatch
Wait for the specified period of time

minimum temperature
2008.50 Kuga 8/2011
General equipment symbols
The general equipment symbols are used to show

where to use which type of general equipment to
carry out a procedure step.
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100-00-37
100-00-37
E89019
Item
Description
Wear protective gloves
Wear face guard
Wear safety goggles
Wear ear protectors
Wear safety goggles and ear protectors
Wear a respirator
2008.50 Kuga 8/2011
Prohibition - Health and safety symbols and

component damage
The prohibition symbols are used to prohibit the

specified actions to avoid or at least reduce
possible component damage and health and safety
risks.
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General Information
100-00-33
100-00-33
E88979
Item
Description
Item
Description
Hot air gun
Scraper
Soldering iron
Scriber
2008.50 Kuga 8/2011
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General Information
100-00-34
100-00-34

Item
Description
Item
Description
Securing strap
14
Wedge
File with a specified size
15
Pin Punch
Center punch
16
Air blow gun
Marker
17
Mallet
Metal inert gas (MIG) welding equipment
18
Relocate and support the component
10
Hose clamp
11
Interior trim remover
12
Vacuum cleaner
13
Strap wrench
Material symbols
The material symbols are used to show where to

use which type of material to carry out a procedure
step.
E88980
Item
Description
Remove/Install the specified blind rivet
Apply tape to the specified

component/area
Remove/Install the specified cable tie
2008.50 Kuga 8/2011
Miscellaneous symbols
These symbols provide further information that is

required to carry out a procedure step.
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100-00-38
100-00-38
E89020
Item
Description
Item
Description
General prohibition symbol
Do not switch
No naked flames
No grinding
No smoking
No water
Do not touch
2008.50 Kuga 8/2011
Warning symbols - Health and safety and component

damage
The warning symbols are used to advise on

hazardous conditions to avoid or at least reduce
possible component damage and health and safety
risks.
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100-00-35
100-00-35
12
11
13
E88981
Item
Description
Set the ignition switch to the 0 position
Set the ignition switch to the II position
2008.50 Kuga 8/2011
Item
Description
The procedure step requires the aid of the

specified number of supporting technicians
G955392en

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General Information
100-00-39
100-00-39
12
13
E89021
Item
Description
Item
Description
Hazardous voltage/Electrical
shock/Electrocution
Corrosive material
Lifting hazard
Fire Hazard/Highly flammable
10
Hand crush/Force from above
Burn hazard/Hot surface
11
Cutting of fingers or hand
Automatic start-up
12
Pressure hazard
Toxic
13
Explosive material
Battery hazard
Invisible laser radiation. Do not view

directly with optical instruments
(magnifiers). Class 1M laser product
2008.50 Kuga 8/2011
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100-00-40
100-00-40

Control Diagram symbols - Description and
Operation procedures
These symbols provide further information on the

type of connectivity, direction of flow or type of data
bus of a system.
4
E99427
Item
Description
Mid-speed Controller Area Network (CAN)
High-speed Controller Area Network

(CAN)
Local Interconnect Network (LIN)
Wires crossing not connected
2008.50 Kuga 8/2011
G955392en

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100-00-41
General Information
100-00-41
Steering System Health and Safety Precautions

WARNINGS:
When handling the power steering fluid,
always wear protective goggles and gloves
made of nitril.
EYE CONTACT: Power steering fluid
contains long chain alkyl amine
thiophosphate. Avoid contact with the
eyes. Wash hands thoroughly after
handling. If power steering fluid comes into
contact with the eyes, flush the eyes with
plenty of cold running water for 15
minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SKIN CONTACT: If power steering fluid
comes into contact with the skin, remove
contaminated clothing. Wash affected
areas of skin with soap and water. Seek
medical attention for any persistent skin
irritation or abnormality.
INHALED: If oil mist is inhaled, move a
victim to fresh air. Keep a victim warm and
at rest. Seek immediate medical attention
in cases of throat irritation or coughing.
SWALLOWED: Power steering fluid
contains long chain alkyl amine
thiophosphate. If swallowed, drink plenty
of water. Seek immediate medical attention.
CAUTION: If the power steering fluid is
spilled on the paintwork, the affected area
must be immediately washed down with
cold water.
2008.50 Kuga 8/2011
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100-00-46
General Information
100-00-46

Exhaust Fumes
First Aid
These contain asphyxiating, harmful and toxic

chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under
conditions of adequate exhaust extraction or
general ventilation and not in confined spaces.
Apart from meeting any legal requirements it is

desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Gasoline (petrol) engine
In case of cold burns, from alternative fuels, place

affected area in cool to cold water.
There may not be adequate warning of odor or of

irritation before toxic or harmful effects arise. These
may be immediate or delayed.
Individuals affected by inhalation of gases and

fumes should be removed to fresh air immediately.
If effects persist, consult a doctor.
Diesel engine
If liquids are swallowed inadvertently, consult a

doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label.
Soot, discomfort and irritation usually give

adequate warning of hazardous fume
concentrations.
Fibre Insulation
See also Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and
not a chemical effect.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Precautions should be taken to avoid excessive

skin contact through careful organization of work
practices and the use of gloves.
Follow manufacturers instructions.
Fire
Individuals with chronic respiratory diseases,

asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
uncured materials.
See also Welding, Foams, Legal Aspects.

Many of the materials found on or associated with
the repair of vehicles are highly flammable. Some
give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
2008.50 Kuga 8/2011
Unreacted components are irritating and may be

harmful to the skin and eyes. Wear gloves and
goggles.
The components, vapors or spray mists can cause

direct irritation, sensitivity reactions and may be
toxic or harmful.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying; wait until the
vapors/mists have cleared.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
G566527en

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100-00-42
General Information
100-00-42
Health and Safety Precautions

Introduction
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards
or other risks to health. This subsection lists,
alphabetically, some of these hazardous operations
and the materials and equipment associated with
them. Precautions necessary to avoid these
hazards are identified.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should
be carried out with health and safety in mind.
Before using any product the Materials Safety Data
Sheet supplied by the manufacturer or supplier
should be consulted.
inflator as this will lead to the risk of exposure to

Sodium Azide. If a gas generator is ruptured, full
protective clothing should be worn when dealing
with the spillage.
After normal deployment, gloves and safety
goggles must be worn during the handling process.
Deployed air bags should be disposed of in a
plastic bag in accordance with local regulations at
an approved chemical waste site.
For additional information, refer to: Supplemental
Restraint System (SRS) Health and Safety
Precautions (100-00 General Information,
Air Conditioning Refrigerant

Acids and Alkalis
See also Chlorofluorocarbon, Chemical Materials
See also Battery Acids.
Highly flammable, combustible observe No

Smoking policy.
For example caustic soda, sulphuric acid.

Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and
soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive observe No Smoking
policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500C).
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module
and is completely consumed during deployment.
No attempt should be made to open an air bag
2008.50 Kuga 8/2011
Skin contact may result in frostbite.

Instructions given by the manufacturer must be
followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or
eyes, immediately rinse the affected areas with
water. Eyes should also be rinsed with an
appropriate irrigation solution and should not be
rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY.
For additional information, refer to: Air Conditioning
(A/C) System Health and Safety Precautions
(100-00 General Information, Description and
Operation).
Adhesives and Sealers

See also Fire, Chemical Materials.
Highly flammable, flammable, combustible
observe No Smoking policy.
Generally should be stored in No Smoking areas.
Cleanliness and tidiness in use should be
observed, for example disposable paper covering
benches; should be dispensed from applicators
where possible; containers, including secondary
containers, should be labeled appropriately.
G566527en

TO MODEL INDEX
100-00-43
General Information
100-00-43

Solvent-based Adhesives/Sealers - See
Solvents
For two-pack systems see Resin-based and

Isocyanate Adhesives/Sealers.
Follow manufacturers instructions.
Isocyanate (Polyurethane)
Adhesives/Sealers
Water-based Adhesives/Sealers
See also Resin-based Adhesives.
Those based on polymer emulsions and rubber
latexes may contain small amounts of volatile toxic
and harmful chemicals. Skin and eye contact
should be avoided and adequate ventilation
provided during use.
Hot Melt Adhesives

In the solid state, they are safe. In the molten state
they may cause burns and health hazards may
arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a
thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for

example Epoxide and Formaldehyde
Resin-based
Mixing should be carried out in well ventilated
areas, as harmful or toxic volatile chemicals may
be released.
Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
of toxic or harmful chemicals through the skin.
Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and
eye contact.
Anaerobic, Cyanoacrylate (super-glues)

and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin
and respiratory tract. Some are eye irritants.
Individuals suffering from asthma or respiratory

allergies should not work with or near these
materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to
vapor concentrations may result in adverse health
effects.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort
and possible damage.
Any spraying should preferably be carried out in
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory
protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
For additional information, refer to: Engine Cooling
System Health and Safety Precautions (100-00
General Information, Description and Operation).
Skin and eye contact should be avoided and the

manufacturers instructions followed.
Asbestos
Cyanoacrylate adhesives (super-glues) MUST NOT

contact the skin or eyes. If skin or eye tissue is
bonded, cover with a clean moist pad and SEEK
IMMEDIATE MEDICAL ATTENTION. Do not
attempt to pull tissue apart. Use in well ventilated
areas as vapors can cause irritation to the nose
and eyes.
See also Warning Symbols on Vehicles at the end

of this subsection.
2008.50 Kuga 8/2011
Breathing asbestos dust may cause lung damage

or, in some cases, cancer.
Used in brake and clutch linings, transmission
brake bands and gaskets.
G566527en

TO MODEL INDEX
100-00-47
General Information
100-00-47

foams should be conducted with extraction
ventilation. See also the vehicle Body Repair
Manual.
Freon
See Air Conditioning Refrigerant.
Gases such as oxygen, acetylene, argon and

propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the valve
gear attached. The contents of each cylinder
should be clearly identified by appropriate
markings.
See also, Fire, Legal Aspects, Chemicals and

Solvents.
Cylinders should be stored in well-ventilated

enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
and propane, should not be stored in close
proximity to oxygen cylinders.
Avoid skin contact with fuel where possible. Should

contact occur, wash the affected skin with soap
and water.
Care should be exercised to prevent leaks from

gas cylinders and lines, and to avoid sources of
ignition.
Gasoline (Petrol)
Only trained personnel should undertake work

involving gas cylinders.
Highly flammable - observe No Smoking policy.
Gases
Fuels
For additional information, refer to: Petrol and

Petrol-Ethanol Fuel Systems Health and Safety
See Gas Cylinders.
Gaskets (Fluoroelastomer)
Gas-oil (Diesel Fuel)
See Viton.
Kerosene (Paraffin)
General Workshop Tools and

Equipment
Used also as heating fuel, solvent and cleaning

agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause
irritation or dermatitis. Splashes in the eye may be
slightly irritating.
In normal circumstances the low volatility does not
give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there
is adequate ventilation.
Gas Cylinders
See also Fire.
2008.50 Kuga 8/2011
It is essential that all tools and equipment are

maintained in good condition and that the correct
safety equipment is used where required.
Never use tools or equipment for any purpose other
than that for which they were designed. Never
overload equipment such as hoists, jacks, axle and
chassis stands or lifting slings. Damage caused by
overloading is not always immediately apparent
and may result in a fatal failure the next time that
the equipment is used.
Do not use damaged or defective tools or
equipment, particularly high-speed equipment such
as grinding wheels. A damaged grinding wheel can
disintegrate without warning and cause serious
injury.
Wear suitable eye protection when using grinding,
chiseling or sand blasting equipment.
Wear a suitable breathing mask when using
abrasive blasting equipment, working with
asbestos-based materials or using spraying
equipment.
G566527en

TO MODEL INDEX
100-00-44
General Information
100-00-44

The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
Asbestos dust waste should be dampened, placed
in a sealed container and marked for safe disposal.
If any cutting or drilling is attempted on materials
containing asbestos the item should be dampened
and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
For additional information, refer to: Battery and
Battery Charging Health and Safety Precautions
Operation).
Brake and Clutch Linings and Pads

See Asbestos.
Brake Fluids (Polyalkylene Glycols)

See also Fire.
For additional information, refer to: Brake System
Health and Safety Precautions (100-00 General
Information, Description and Operation).
Chemical Materials - Do's

Do carefully read and observe hazard and
precaution warnings given on material
containers (labels) and in any accompanying
leaflets, posters or other instructions. Material
health and safety data sheets can be obtained
from manufacturers.
Do remove chemical materials from the skin
and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it
cleaned.
Do organize work practices and protective
clothing to avoid soiling of the skin and eyes;
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion
hazards.
Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities when
handling chemical materials.
Do keep work areas clean, uncluttered and free
of spills.
Do store chemical materials according to
national and local regulations.
Do keep chemical materials out of the reach of
children.
Chemical Materials - Do Nots
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise
to hazardous fumes and dusts.
The effects of excessive exposure to chemicals
may be immediate or delayed; briefly experienced
or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
2008.50 Kuga 8/2011
Do not mix chemical materials except under the

manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off
toxic or harmful fumes or become explosive
when mixed together.
Do not spray chemical materials, particularly
those based on solvents, in confined spaces,
for example when people are inside a vehicle.
Do not apply heat or flame to chemical materials
except under the manufacturers instructions.
Some are highly flammable and some may
release toxic or harmful fumes.
Do not leave containers open. Fumes given off
can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas such
as pits.
Do not transfer chemical materials to unlabelled
containers.
Do not clean hands or clothing with chemicals.
Chemicals, particularly solvents and fuels, will
dry the skin and may cause irritation leading to
G566527en

TO MODEL INDEX
100-00-45
General Information
100-00-45

dermatitis or be absorbed through the skin in
toxic or harmful quantities.
Do not use emptied containers for other
materials except when they have been cleaned
under supervised conditions.
Do not sniff or smell chemical materials. Brief
exposure to high concentrations of fumes can
be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
Decreased filtration of ultraviolet radiation may
result in increases in skin cancer, cataracts and
immune system suppression in humans, as well
as decreased productivity of crops and aquatic
systems.
CFCs are used primarily as refrigerants in vehicle
air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads

See Asbestos.
Corrosion Protection Materials

See also Solvents, Fire.
Highly flammable, flammable observe No
Smoking policy.
These materials are varied and the manufacturers
instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and
eye contact should be avoided. They should only
be sprayed in conditions of adequate ventilation
and not in confined spaces.
Cutting
Dusts
Powder, dusts or clouds may be irritant, harmful
or toxic. Avoid breathing dusts from powdery
chemical materials or those arising from dry
abrasion operations. Wear respiratory protection
if ventilation is inadequate.
Fine dusts of combustible material can present an
explosion hazard. Avoid explosive limits and
sources of ignition.
Electric Shock
Electric shock can result from the use of faulty
electrical equipment or from the misuse of
equipment in good condition.
Make sure that electrical equipment is maintained
in good condition and frequently tested. Faulty
equipment should be labeled and preferably
removed from the workstation.
Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Make sure that electrical equipment and flexes do
not come into contact with water.
Make sure that electrical equipment is protected
by the correct rated fuse.
Never misuse electrical equipment and never use
equipment that is in any way faulty. The results
could be fatal.
Make sure that the cables of mobile electrical
equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Make sure that the designated electrical workers
are trained in basic First Aid.
In cases of electrocution:
switch off the power supply before approaching
the victim.
if this is not possible push or drag the victim
from the source of electricity using dry
non-conductive material.
commence resuscitation if trained to do so.
SUMMON MEDICAL ASSISTANCE.
See Welding.
Engine Oils
Dewaxing
See Lubricants and Grease.
See Solvents and Fuels (Kerosene).
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100-00-48

Make sure there is adequate ventilation to control
dusts, mists and fumes.
High Pressure Air, Lubrication and Oil

Test Equipment
See also Lubricants and Greases.
Always keep high-pressure equipment in good
condition, and regularly maintained, particularly at
joints and unions.
Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause
serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to
health and safety in the use and disposal of
materials and equipment in a workshop.
For a safe working environment and to avoid
environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country, published
by both national and local authorities.
Lubricants and Greases

Avoid all prolonged and repeated contact with
mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Transmission Fluids
Safety instructions
Certain Transmission and Power Steering fluids
supplied to Ford may contain additives which have
the potential to cause skin disease (dermatitis) to
exposed persons. The dermatitis may be irritant
or allergic in nature. Risks are higher where
prolonged or repeated skin contact with a fluid may
occur. These fluids are used for vehicle initial fill
and service purposes. This sub-section is to:
2008.50 Kuga 8/2011
Inform Service personnel who may come into

contact with these vehicle fluids (hazard
communication).
Summarise appropriate workplace control
measures and personal protective equipment
requirements.
Draw attention to the existence of Material
Safety Datasheets (MSDS's) for the fluids
(available from Ford Customer Service Division).
These MSDS's contain detailed information on
hazards and appropriate controls.
Control measures
Workplace risk assessments made under national
chemical control regulations should identify
operations involving the fluids as potentially
hazardous and specify workplace control and
worker awareness measures. In such
circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
specifies hazards and control measures in detail
should be made available for guidance.
Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin
contact. Work practices should be organised so as
to minimise the potential for skin contact. This may
include the use of drip trays, absorbents, correct
fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
should wear impervious gloves made from nitrile
rubber, certified to a chemical protection standard,
e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety
products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves
become torn or contaminated on the inside they
should be replaced. Eye protection with safety
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products
may offer some supplementary protection, but such
barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids,
wash the area thoroughly with soap or skin
cleanser and water.
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Accidental eye contact should be dealt with as per
normal first aid practices, by flushing the eyes with
an eye wash or clean cool water for 10 minutes,
after which medical attention should be obtained.
Remove and launder clothing which becomes
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where
skin exposure may have occurred.
It is important that personnel do not smoke, eat or
drink whilst handling the fluids or affected
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Label any decanted fluid properly/use an equivalent
label to that on original product containers.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous
waste.
waste disposal sites, or to the waste oil reclamation

trade. If in doubt, contact the relevant local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down
sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels,
which could, in time, damage hearing. In these
cases, suitable ear protection must be worn.
Noise Insulation Materials

See Foams, Fibre Insulation.
O-Rings (Fluoroelastomer)
See Viton.
Paints
Safety Data Sheets
See also Solvents, Chemical Materials.
Safety Data Sheets, which detail specific material

handling instructions and precautions are available
from the respective national sales company, and
via internet www.msds.ford.com.
Highly flammable, flammable - observe No

Smoking policy
Used Engine Oil
Can contain harmful or toxic pigments, driers and

other components as well as solvents. Spraying
should be carried out only with adequate
ventilation.
Prolonged and repeated contact with mineral oil

will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided.
Do not employ used engine oils as lubricants or
for any application where appreciable skin contact
is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
One Pack
Two Pack
Can also contain harmful and toxic unreacted
resins and resin hardening agents. The
manufacturers instructions should be followed. See
also Resin-based Adhesives and Isocyanate
Adhesives and Sealers under Adhesives and
Sealers.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals
working in booths should wear appropriate
respiratory protection. Those doing small-scale
repair work in the open workshop should wear
air-fed respirators.
Dispose of used oil and used oil filters through

authorized waste disposal contractors or licensed
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Pressurized Equipment
there might not be adequate warning indications,

can cause more serious toxic or harmful effects.
See High Pressure Air, Lubrication and Oil Test

Equipment.
Aspiration into the lungs, for example through

vomiting, is the most serious consequence of
swallowing.
Solder
Avoid splashes to the skin, eyes and clothing. Wear

protective gloves, goggles and clothing if
necessary.
Solders are mixtures of metals such that the

melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead
fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they
are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
Solder spillage and filings should be collected and
removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of
solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene),
Fire.
For example acetone, white spirit, toluene, xylene,
trichloroethane.
Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Make sure there is good ventilation when in use,

avoid breathing fumes, vapors and spray mists and
keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, for
example paints, adhesive, coatings, use extraction
ventilation or personal respiratory protection in the
absence of adequate general ventilation.
Do not apply heat or flame except under specific
and detailed manufacturers instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
suspended or raised load, for example a
suspended engine.
Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
and suitable for the job, in good condition and
regularly maintained.
Transmission Brake Bands
Some may be highly flammable or flammable.

Skin contact will degrease the skin and may result
in irritation and dermatitis following repeated or
prolonged contact. Some can be absorbed through
the skin in toxic or harmful quantities.
See Asbestos.
Splashes in the eye may cause severe irritation

and could lead to loss of vision.
See Corrosion Protection.
Brief exposure of high concentrations of vapors or

mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness.
Viton
Repeated or prolonged exposure to excessive but

lower concentrations of vapors or mists, for which
2008.50 Kuga 8/2011
Underseal
In common with many other manufacturers

vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'.
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Viton is a fluoroelastomer, that is a synthetic rubber
type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
all types. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel
and Tecmoflon.
When used under design conditions
fluoroelastomers are perfectly safe. If, however,
they are exposed to temperatures in excess of
400C, the material will not burn, but will
decompose, and one of the products formed is
hydrofluoric acid.
This acid is extremely corrosive and may be
absorbed directly, through contact, into the general
body system.
O-rings, seals or gaskets which have been exposed
to very high temperatures will appear charred or
as a black sticky substance.
DO NOT; under any circumstances touch them or
the attached components.
Enquiries should be made to determine whether
Viton or any other fluoroelastomer has been used
in the affected O-ring, seal or gasket. If they are of
natural rubber or nitrile there is no hazard. If in
doubt, be cautious, as the material may be Viton
or any fluoroelastomer.
If Viton or any other fluoroelastomers have been
used, the affected area should be decontaminated
before the commencement of work.
Disposable heavy duty plastic gloves should be
worn at all times, and the affected area washed
down using wire wool and a limewater (calcium
hydroxide) solution to neutralize the acid before
disposing of the decomposed Viton residue and
final cleaning of the area. After use, the plastic
gloves should be discarded carefully and safely.
Welding
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal
to be emitted at a high velocity, and the eyes and
skin must be protected.
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Arc Welding
This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin burns
to the operator and to other persons nearby.
Gas-shielded welding processes are particularly
hazardous in this respect. Personal protection must
be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO
REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to
emit microwaves which dry out the fluid between
the lens and the eye. This may result in blindness
when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye
and skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded, the rods and
from any applied coatings or contamination on the
surfaces being worked on. These gases and fumes
may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
the fumes from the working area may be necessary
particularly in cases where the general ventilation
is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces
where adequate ventilation cannot be provided,
air-fed respirators may be necessary.
Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding
and cutting, and special care must be taken to
prevent leakage of these gases, with consequent
risk of fire and explosion.
The process will produce metal spatter and eye
and skin protection is necessary.
The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken
to avoid inhalation of fumes and expert advice may
be required.
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SPECIAL PRECAUTIONS MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING TAKES
PLACE ON VESSELS, WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles

Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of owners/operators and
persons carrying out service or repair operations
on the vehicle.
TIM0101003
3. Vehicles and replacement components which

contain asbestos are identified by this symbol.
See Asbestos in this subsection.
The most commonly found decals are reproduced

below together with an explanation of the warnings.
TIM0101004
TIM0101001
1. Components or assemblies displaying the

caution triangle and open book symbol advise
consultation of the relevant section of the owner
literature before touching or attempting
adjustments of any kind.
4. Components or assemblies displaying this

symbol give warning that the component
contains a corrosive substance. See Acids and
Alkalis in this subsection.
TIM0101005
TIM0101002
2. Components or assemblies displaying the

warning triangle with the `electrified' arrow and
open book symbol give warning of inherent high
voltages. Never touch these with the engine
running or the ignition switched on. See Electric
Shock in this subsection.
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5. Displaying the caution circle with a deleted

lighted match symbol, caution against the use
of naked lights or flames within the immediate
vicinity due to the presence of highly flammable
or explosive liquids or vapors. See Fire in this
subsection.
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instructions. Failure to follow this
instruction may result in personal injury
or damage to components.
It is of fundamental importance that certain
essential equipment, for example torque wrenches,
multimeters, exhaust gas analyzers or rolling roads,
are regularly calibrated in accordance with the
manufacturers instructions.
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TIM0101006
6. Displaying this symbol (normally in conjunction

with 5 above) warn of the presence of potentially
explosive matter within the immediate vicinity.
TIM0101008
7. Displaying this symbol warn that children should

not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
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General Information
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Standard Workshop Practices

Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
the parking brake is applied or the wheels are
securely chocked to prevent the vehicle moving
forwards or backwards.
the key is removed from key operated hood
locks before any work is carried out around the
front of the vehicle.
if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
there is adequate room to raise the vehicle and
remove the wheels, if necessary.
fender covers are always fitted if any work is to
be carried out in the engine compartment.
the battery is disconnected if working on the
engine, underneath the vehicle, or if the vehicle
is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a surge
of current causing damage to the internal
components of the generator.
if using welding equipment on the vehicle, a
suitable fire extinguisher is readily available.
Towing the Vehicle

WARNING: When the vehicle is being
towed, the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then will
the steering, turn signal lamps, horn and
stop lamps be operational. Failure to follow
these instructions may result in personal
injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
(Neutral). Never tow a vehicle with automatic

transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using

Jumper Cables
WARNING: If the slave battery has recently
been charged and is gassing, cover the
vent plugs or covers with a damp cloth to
reduce the risk of explosion should arcing
occur when connecting the jumper cables.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
While it is not recommended that the
vehicle is jump started, it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
an instance, the discharged battery must
be recharged immediately after jump
starting to avoid permanent damage.
Always make sure that the jumper cables are
adequate for the task. Heavy duty cables must
be used.
Always make sure that the slave battery is of
the same voltage as the vehicle battery. The
batteries must be connected in parallel.
Always make sure that switched electric circuits
are switched off before connecting jumper
cables. This reduces the risk of arcing occurring
when the final connection is made.
When a vehicle with automatic transmission is

towed, the gear selector must be in position N
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Solvents, Sealants and Adhesives

Introduction
WARNING: Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off fumes
which can be dangerous to health. Always
follow the manufacturers instructions. If in
doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION: If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
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before disconnecting or dismantling components
or assemblies.
Components should be thoroughly cleaned before
inspection prior to reassembly.
Cleaning Methods:
TIM0103001
WARNING: Make sure that the ends of the

jumper cables do not touch each other or
ground against the vehicle body at any
time while the cables are attached to the
battery. A fully charged battery, if shorted
through jumper cables, can discharge at
a rate well above 1000 amps causing
violent arcing and very rapid heating of the
jumper cables and terminals, and can even
cause the battery to explode. Failure to
follow these instructions may result in
personal injury.
Always connect the jumper cables in the following
sequence:
Slave battery positive first and then vehicle
battery positive.
Slave battery negative next and then vehicle
ground at least 12 inches (300 mm) from the
battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before
disconnecting the jumper cables.
Before removing the jumper cables from the vehicle
that had the discharged battery, switch on the
heater blower (high) or the heated rear window, to
reduce the voltage peak when the cables are
removed.
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short
the ends of the cables.
Do not rely on the generator to restore a
discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours
continuous driving with no additional loads placed
on the battery.
Component Cleaning
To prevent the ingress of dirt, accumulations of
loose dirt and greasy deposits should be removed
2008.50 Kuga 8/2011
Dry cleaning.
Removal of loose dirt with soft or cable brushes.
Scraping dirt off with a piece of metal or wood.
Wiping off with a rag.
WARNING: Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
Blowing dirt off with compressed air.
Removal of dry dust using vacuum equipment.
This method must always be used to remove
friction lining material dust (asbestos particles).
Steam cleaning.
WARNING: Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
Various solvents are available which are suitable
for component cleaning. Some components, such
as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
refer to Solvents, Sealers and Adhesives or to
the section of the manual relevant to the
component.
Calibration of Essential Measuring

Equipment
WARNING: Equipment, which requires
regular calibration, must be calibrated in
accordance with the manufacturers
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Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
that the parking brake is applied.

that the gear lever is in the neutral position.
that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
that the ignition controlled warning lamps are
illuminated.
that the engine temperature gauge registers a
reading compatible with the engine temperature.
that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing

CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
With the ignition switched off, check:
During the road or roller test, check:
the engine oil level.

the engine coolant level.
the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
that there is sufficient fuel in the tank to
complete the test.
all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
that the clutch pedal operation is not stiff or

heavy.
that the initial gear engagement is smooth and
there is no evidence of clutch drag.
that the parking brake control operates smoothly
and releases quickly and completely.
that the clutch takes up the drive smoothly,
without slip or judder.
that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
that the steering does not pull to one side and
self centers smoothly after cornering.
Starting the Engine

NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
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that the speedometer, coolant temperature
gauge and tachometer (if equipped) register the
correct readings and operate correctly.
that the switches and controls operate smoothly
and positively, warning and indicator lamps
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
that the heating and ventilation systems operate
correctly and effectively.
the brake operation and efficiency.
oil, coolant, hydraulic, air and fuel leaks.

abnormal temperature of any moving
components or assemblies, for example wheel
hubs, transmission and axle, which might
indicate over tightness or lack of lubrication.
Brake Testing
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
For additional information, refer to: Health
and Safety Precautions (100-00 General
CAUTIONS:
Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake
applications should not be carried out with
new brake pads/discs or linings/drums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2008.50 Kuga 8/2011
G17375en

TO MODEL INDEX
100-00-60
General Information
100-00-60
Air Conditioning (A/C) System Health and Safety Precautions

WARNINGS:
Only qualified technicians are allowed to
work on air conditioning (A/C) systems.
Air conditioning (A/C) system components
can become particularly hot or cold.
Make sure that the air conditioning (A/C)
system is at ambient temperature before
carrying out any repair.
When handling refrigerants, always wear
protective goggles and gloves made of
fluoroelastomer. Leather or fabric gloves
are not suitable.
SKIN CONTACT: If liquid refrigerant comes
into contact with the skin, it produces
severe frostbite. Immediately flush affected
areas with plenty of cold running water for
15 minutes. Seek medical attention.
EYE CONTACT: If refrigerant comes into
contact with the eyes, immediately flush
the eyes with plenty of running water for
15 minutes. Seek medical attention.
INHALED: Toxic gases generated when
refrigerant is heated are hazardous to
health. The gases have an irritating smell
and can cause lung damage. The
symptoms can continue for a long time
after having been in contact with the gases.
The gases can cause lung damage even if
the amount of gas in the air is too small to
smell.
Refrigerant is flammable and explosive.
Only use special tools, equipment and

lubricants that are approved for the type
of refrigerant being used.
Always follow the manufacturers
instructions for the correct servicing unit
operating procedure.
CAUTIONS:
Do not mix refrigerant oils for different
types of refrigerant.
Never mix different types of refrigerant or
equipment intended for them.
Only use refrigerant in gas form when
filling the system through the low-pressure
connection.
Only use refrigerant in liquid form when
filling the system through the
high-pressure connection.
Refrigerant attacks certain plastics. Only
use seals suitable for refrigerant.
If the air conditioning (A/C) compressor is
damaged, the fixed orifice tube can
become blocked with metal particles.
Any sort of blockage in the refrigerant
circuit will damage the air conditioning
(A/C) compressor irreparably.
If the air conditioning (A/C) system has
been opened for a period greater than 2
hours, a new receiver drier must be
installed and the evacuating time to be
increased by a minimum of 2 hours.
Make sure that refrigerant bottles are not

exposed to temperatures greater than 45C.
NOTE: New air conditioning (A/C) compressors

are delivered prefilled.
Make sure that the local regulations

regarding work on air conditioning (A/C)
systems are adhered to.
NOTE: Refrigerant oil in new air conditioning (A/C)

compressors can contain Teflon, visible as white
particles, which will not harm the system.
Make sure that refrigerant bottles are

closed properly.
Gaseous refrigerant has a higher density
than air. There is a danger of suffocation
when working close to the ground or in
workshop pits.
Provide adequate ventilation when
handling refrigerant.
Never release refrigerant into the
atmosphere.
2008.50 Kuga 8/2011
G548993en

TO MODEL INDEX
100-00-61
General Information
100-00-61
Battery and Battery Charging Health and Safety Precautions

WARNINGS:
Batteries contain sulphuric acid, avoid
contact with skin, eyes or clothing. Wear
safety goggles when working near the
battery to protect against possible
splashing of the acid solution.
EYE CONTACT: If acid comes into contact
with the eyes, flush immediately with
plenty of running water for a minimum of
15 minutes. Seek immediate medical
attention.
SKIN CONTACT: If acid comes into contact
with the skin, flush immediately with plenty
of running water for a minimum of 15
minutes. Seek immediate medical attention.
SWALLOWED: If acid is swallowed, rinse
the mouth with plenty of water and then
drink plenty of water or milk. Do not induce
vomiting. Seek immediate medical
attention.
Batteries normally produce explosive
gases. Do not allow naked flames, sparks
or lighted substances to come near the
battery.
When charging the battery shield your face
and wear safety goggles. Provide adequate
ventilation.
CAUTION: Boost charging with excessive
current or voltage above 16 volts will
damage the battery.
2008.50 Kuga 8/2011
G548994en

TO MODEL INDEX
100-00-62
General Information
100-00-62
Brake System Health and Safety Precautions

WARNINGS:
EYE CONTACT: Brake fluid contains
polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fluid
comes into contact with the eyes, flush the
eyes with plenty of cold running water for
15 minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SWALLOWED: Brake fluid contains
polyglycol ethers and polyglycols. If
swallowed, drink plenty of water. Seek
immediate medical attention.
INHALED: Dust from friction materials can
be harmful if inhaled.
Only use new specified brake fluid from
airtight containers.
CAUTION: If brake fluid is spilled on the
paintwork, the affected area must be
immediately washed down with cold water.
2008.50 Kuga 8/2011
G565862en

TO MODEL INDEX
100-00-63
General Information
100-00-63
Engine Cooling System Health and Safety Precautions

WARNINGS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Vapors may be given off from antifreeze
when heated. Avoid breathing these
vapors.
SKIN CONTACT: Antifreeze may be
absorbed through the skin in toxic or
harmful quantities.
SWALLOWED: If antifreeze is swallowed,
drink plenty of water, induce vomiting.
Seek immediate medical attention.
Antifreeze must not be used in any cooling
or industrial water system that is
connected or linked to general water
supplies.
2008.50 Kuga 8/2011
G548995en

TO MODEL INDEX
100-00-66
General Information
100-00-66
Window Glass Health and Safety Precautions

WARNINGS:
Cured polyurethane (PU) adhesive can
degrade if subjected to high temperatures.
Isocyanide compounds can be released
when grinding or welding in close
proximity to cured PU adhesive.
SKIN CONTACT: Prolonged exposure to
polyurethane (PU) adhesive may cause
skin irritation. If PU adhesive comes into
contact with the skin, remove any
contaminated clothing. Immediately wash
the skin with soap and water. Seek medical
attention for any persistent skin irritation
or abnormality.
EYE CONTACT: Polyurethane (PU)
adhesive may cause severe irritation or
damage. If PU adhesive comes into contact
with the eyes, immediately flush eyes with
plenty of running water for at least 15
minutes. Seek immediate medical attention.
SWALLOWED: If polyurethane (PU)
adhesive is swallowed, flush the mouth
thoroughly. Do not induce vomiting.
Provide rest, warmth and fresh air. Seek
INHALED: Persons having a respiratory
allergy may have an allergic reaction when
handling polyurethane (PU) adhesive.
INHALED: Polyurethane (PU) adhesive can
cause asthma like symptoms. Isocyanate
vapor from primer or PU adhesive can
cause allergies in the respiratory tract.
INHALED: If polyurethane (PU) adhesive
fumes are inhaled, move victim to fresh
air. Provide oxygen if necessary. If
breathing stops, provide artificial
respiration. Keep a victim warm and at rest.
CAUTIONS:
Make sure that the direct glazing for
bonded glass cutting blades are changed
where the cutting depth changes to avoid
damage to the body and trim panels.
During the curing period of the PU
adhesive, the door windows must be left
open to avoid a build up of pressure when
the doors are opened and closed.
2008.50 Kuga 8/2011
G548999en

TO MODEL INDEX
100-00-64
General Information
100-00-64
Petrol and Petrol-Ethanol Fuel Systems Health and Safety

Precautions
WARNINGS:
Fuel may not give adequate warning before
toxic or harmful effects arise.
Exposure to fuel can be harmful and can
cause severe health damage or death.
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Highly flammable mixtures are always
present and may ignite when working on
fuel systems. Do not allow naked flames,
sparks or lighted substances to come near
fuel related components.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of
direct sunlight and in a cool area. Keep
away from heat sources, ignition sources
and oxidizing agents.
SKIN CONTACT: Excessive or prolonged
skin contact with diesel fuel may cause
serious skin disorders including skin
cancer.
has stopped, apply artificial respiration.

INHALED: Fuel is toxic to the respiratory
and other body systems. Exposure may
result in various symptoms including
drowsiness, unconsciousness or severe
health damage. Move a victim to fresh air.
Keep a victim warm and at rest. If
unconscious, place in the recovery
position. If not breathing, apply artificial
respiration. Give cardiac massage if
necessary. Seek immediate medical
attention.
CAUTIONS:
Fuel injection equipment is manufactured
to very precise tolerances and fine
clearances. It is essential that absolute
cleanliness is observed when working with
these components.
Make sure that the workshop area in which
the vehicle is being worked on is as clean
and as dust free as possible.
SKIN CONTACT: Fuel is mildly irritating to

the skin and may cause dermatitis due to
defatting effect. Remove contaminated
clothing. Wash affected areas of skin with
soap and water. Seek medical attention for
any persistent skin irritation or
abnormality. Wash contaminated clothing
before reuse.
EYE CONTACT: Fuel is mildly irritating to
the eyes. Flush with plenty of running
water, blinking as often as possible. Do not
force the eyelid open. Seek medical
attention for any persistent eye irritation
or abnormality.
SWALLOWED: Fuel is moderately toxic
and tends to foam on vomiting. If drawn
into the lungs, inflammation may develop.
Do not induce vomiting. If spontaneous
vomiting occurs place the victim in a
forward position to reduce the risk of fuel
being drawn into the lungs. Give nothing
by mouth. If breathing but unconscious,
place in the recovery position. If breathing
2008.50 Kuga 8/2011
G548996en

TO MODEL INDEX
100-00-65
General Information
100-00-65
Supplemental Restraint System (SRS) Health and Safety

Precautions
WARNINGS:
Only qualified technicians are allowed to
work on pyrotechnic components.
INHALED: Exposure to pyrotechnic residue
may cause low blood pressure, severe
headache, irritation of mucous membranes,
fainting, shortness of breath or rapid pulse.
Move a victim to fresh air. Seek immediate
medical attention.
EYE CONTACT: Exposure to unburned
pyrotechnic residue may cause irritation,
burning and etching of the eyes. Flush
immediately with plenty of cold running
water for at least 15 minutes. Seek
EYE CONTACT: Exposure to burned
pyrotechnic residue may cause irritation,
burning and etching of the eyes. Flush
immediately with diluted boric acid
solution. Seek immediate medical
attention.
SKIN CONTACT: Unburned pyrotechnic
residue may be rapidly absorbed through
the skin in toxic quantities. Wash
immediately with plenty of soap and water.
Seek medical attention.
SKIN CONTACT: Burned pyrotechnic
residue may be rapidly absorbed through
the skin in toxic quantities. Wash with
plenty of water. Do not use soap. Seek
medical attention.
SWALLOWED: Unburned pyrotechnic
residue is extremely toxic. If conscious
drink plenty of water then induce vomiting.
Seek immediate medical attention. If
unconscious, or in convulsions do not
attempt to induce vomiting or give
anything by mouth. Seek immediate
medical attention.
SWALLOWED: Burned pyrotechnic residue
is extremely toxic. Drink plenty of water
and seek immediate medical attention.
If permenantly disabling or enabling the

passenger air bag a new seat belt for
vehicles without or with a passenger air
bag must be installed.
Undeployed pyrotechnic components must
not be deployed in the vehicle.
Pyrotechnic components must be deployed
following local regulations.
Check thoroughly that no loose objects
can be spread during the deployment of
pyrotechnic components.
Pyrotechnic components must be
transported following local regulations.
Never carry out any electrical measurement
on disconnected, undeployed pyrotechnic
components.
Pyrotechnic components must not be
disassembled.
Pyrotechnic components are not
interchangeable between vehicles.
Always carry a live air bag module away
from the body with the air bag or trim cover
pointing upwards.
Live air bag modules must be placed in a
suitable cage when removed from the
vehicle. The air bag or trim cover must be
facing upwards.
Do not install a rearward facing child safety
seat to the passenger seat with an
activated passenger air bag.
CAUTIONS:
Pyrotechnic components must not be
subjected to temperatures higher than
110C.
Never install aftermarket accessories to
the vehicle on or adjacent to the
supplemental restraint system module.
The deployment key must only be

accessible to authorized personnel.
Make sure that the deployment key remains
removed from the deployment equipment
except during deployment.
2008.50 Kuga 8/2011
G548998en

TO MODEL INDEX
100-00-67
General Information
100-00-67
Body Repair Health and Safety and General Precautions

General
Appropriate repair methods and carrying out repair
and paint jobs correctly is particularly important to
the operating safety of vehicles and the safety of
people.
WARNING: There is danger of injury
through:
High voltage when electrical welding.
Do not perform welding work in a damp
environment or on a wet substrate. Use
suitable insulation underneath.
Welding spatter and UV radiation.
Wear protective clothing, gloves and welding
mask or welding goggles.
Fire, explosion and hot surfaces in the work
area.
Always have a suitable fire extinguisher
available when using welding or heating
equipment.
Remove flammable substances from the
danger area. Remove the fuel tank and fuel
pipes and hoses.
Welding and grinding near the battery
presents the danger of explosion. Remove
the battery before you start working.
During paint work there is an increased
danger of fire or explosion. Prevent any
sparks being created. Fire, open light and
smoking are forbidden.
Always ventilate the workplace well and use
an extraction system.
Wear protective footwear made from
anti-static material.
Only use tools made of wood, brass or
copper to clean stands and extraction ducts.
Do not use tools made of steel.
Only fill or decant paint materials in a
specially marked area.
2008.50 Kuga 8/2011
Inhalation and/or absorption through the skin of

harmful substances.
Welding fumes grinding dusts and solvent
vapours can be extremely harmful to the
health.
Sealants, underbody protection and paint
residues must not be burnt down with an
unshielded flame, as this will produce harmful
substances.
Always ventilate the workplace well and use
an extraction system.
Wear protective clothing.
Pyrotechnic components.
Disconnect the battery negative clamp and
cover the battery terminal.
Remove any airbag components.
Noise
Cutting, grinding and alignment work can
cause a noise level over 85 dB (A).
Always wear ear protection.
High Forces.
The various body areas are subject to very
high forces during realignment work. Should
any component suddenly become detached
during this process, there is a very great
danger of injury.
Pulling chains and pulling shackles must be
secured with arrester cables.
As well as these general instructions on the
dangers in body and paint shops, you must
observe:
All valid local national and international
regulations governing Health and Safety at Work
Safety instructions of material equipment and
tool manufacturers
For additional information, refer to: (100-00 General
Information)
Solvents, Sealants and Adhesives (Description
and Operation),
Air Conditioning (A/C) System Health and Safety
Precautions (Description and Operation),
Supplemental Restraint System (SRS) Health
and Safety Precautions (Description and
Operation).
G963390en

TO MODEL INDEX
100-00-68
General Information
100-00-68

Personal protection
Besides the body and limbs, several organs vital
to life are in very particular danger. Because
damage is mostly irreparable, special attention and
comprehensive protection is necessary.
Protective equipment
Always use the appropriate protective equipment:
Protective helmet or welding mask

Breathing protection
Protective clothes gloves and safety boots
Ear defenders
Extraction systems
Always carry out an operational check on your

protective equipment every time before you start
working!
Breathing protection
WARNING: Vapor or spray mist containing

isocyanates as a paint base or hardener
can cause toxic respiratory disease
(conditions similar to asthma) leading to
permanent damage, even when inhaled in
the lowest concentrations
The instructions for use provided by the
manufacturer must be observed when working with
breathing protection equipment.
During painting work and in the preparations for
painting, gases, vapors, mists or dusts can appear
in dangerous concentrations.
Breathing protection devices which are
independent of the local atmosphere are most
suitable.
In these types of isolation systems, a compressed
air hose carries natural air from the compressor
line into the protective mask. During supply, the
air undergoes pressure reduction, water removal,
fine filtration and usually warming to natural breath
temperature.
2008.50 Kuga 8/2011
E59518
Item
Description
Protective hood with fresh air supply
Protective clothing
Protective gloves
Protective footwear
Only for short periods of work or minimal

concentrations of hazardous substances breathing
protection devices with a combination filter is
suitable as breathing protection equipment.
G963390en

TO MODEL INDEX
General Information
100-00-69
100-00-69

For areas of the skin which are not covered by
protective clothing suitable skin protection cleaning
and care agents must be used.
Ear protection
Cutting grinding compressors and extractor fans

and ducts are the main sources of noise in body
and paint shops.
Always wear suitable ear protection like ear plugs
or ear defenders.
E59517
Protection of the vehicle

Item
Description
Activated charcoal filter
Coarse filter
Filter masks with wadding, sponge or colloid filters

and also paper masks are all unsuitable for working
with coating materials because they do not stop
solvent vapors.
Eye protection
Cutting grinding welding solvents and paint bear

fundamental risks for your eyes.
Damage ranging from irritation of the cornea to
incurable illnesses is possible.
Solvents and paint even water based could not
only be absorbed via your skin but also via your
eyes.
Therefore always wear the appropriate eye
protection for your work.
Protective goggles must be inert toward splashes
of solvent, and must have side protection. Best
protection during spray painting is offered by full
mask respirators or helmet respirators with built-in
visor.
Skin protection
Spray painters must wear suitable protective work

clothing (flame-proof and anti-static). Also, when
working with water based materials, comprehensive
skin protection must be worn, because these
materials are very easily absorbed through the
skin.
Change your protective clothing at proper intervals.
Clothes contaminated with coating materials can
easily catch fire.
Do not choose clothes or underwear with a large
content of easy melting synthetic fiber, because
this material considerably increases the danger
and degree of injuries (melted plastic on the skin!).
2008.50 Kuga 8/2011
Protect affected areas from weld spatter and dust

during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time,
there is the likelihood of film rust formation.
Grinding produces tiny spots of damage to the paint
surface, which may cause corrosion. Also use
suitable protective measures to protect the interior
when performing repair operations which relate to
the inside of the vehicle.
For this reason, make sure to:
Use carbon fiber blankets to protect the vehicle
body and the interior.
Use covering film to protect the vehicle body
from grinding dust and metal dust.
Use covering paper to protect the interior from
grinding dust.
In addition, take into account:
Remove fuel supply components as necessary.
Protect working areas which are in danger of
catching fire with a fireproof blanket.
Keep heat away from all components of the air
conditioning system.
Remove all components in the space adjoining
the repair area.
Electronic components
Increased use of comfort and safety electronics in

modern vehicles requires additional attention to be
paid during body work.
Over voltages produced during welding can cause
electronic systems to be damaged. In particular,
the safety instructions for performing welding work
on vehicles with airbag systems must be adhered
to.
WARNING: After disconnecting the power
supply and before performing further work,
a wait time of up to 15 minutes must be
G963390en

TO MODEL INDEX
100-00-70
General Information
100-00-70

maintained, depending on the vehicle.
Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.
For additional information, refer to: (501-20
Supplemental Restraint System)
Driver Air Bag Module (Removal and
Installation),
Passenger Air Bag Module (Removal and
Installation),
Side Air Bag Module (Removal and Installation),
Side Air Curtain Module (Removal and
Installation),
Restraints Control Module (RCM) (Removal and
Installation).
Pay attention to the following points:
Disconnect the battery negative clamp and
cover the battery terminal.
Disconnect the electrical connector at the airbag
control module.
If welding is to be performed directly near a
control module, it must be disconnected or
removed.
Never connect the negative cable of the welder
near an airbag or a control module.
Connect the negative cable of the welder close
to the location of the weld.
2008.50 Kuga 8/2011
G963390en

TO MODEL INDEX
100-02-1
Jacking and Lifting
100-02-1
SECTION 100-02 Jacking and Lifting

CONTENTS
PAGE

Jacking................................................................................................................................
Lifting..................................................................................................................................
100-02-2
100-02-3

TO MODEL INDEX
100-02-2
Jacking and Lifting
100-02-2
Jacking
E100534
2008.50 Kuga 8/2011
G1001882en

TO MODEL INDEX
100-02-3
Jacking and Lifting
100-02-3
Lifting
E96852
2008.50 Kuga 8/2011
G1001883en

TO MODEL INDEX
100-04-1
Noise, Vibration and Harshness
100-04-1
SECTION 100-04 Noise, Vibration and Harshness

CONTENTS
PAGE
DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH)..............................................................................
100-04-2
Inspection and Verification..................................................................................................
100-04-2
Noise Diagnostic Procedure...............................................................................................
100-04-2
Road Test........................................................................................................................... 100-04-3
Road Test Quick Checks....................................................................................................
100-04-3
Road Conditions................................................................................................................. 100-04-4
Vehicle Preparation............................................................................................................ 100-04-4
Power Steering Conditions.................................................................................................
100-04-4
Power Steering Operation Noise Check.............................................................................
100-04-4
Symptom Chart................................................................................................................... 100-04-7
Pinpoint Tests..................................................................................................................... 100-04-14

TO MODEL INDEX
100-04-3
100-04-3

Noise Conditions
Gear noise is typically a howling or whining due
to gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds
like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64 km/h (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
Knock is very similar to chuckle, though it may
be louder and occurs on acceleration or
deceleration. The teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
out-of-balance front or rear wheels.
out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
damaged powertrain/drivetrain mounts.
excessively high constant velocity (CV) joint
operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving
conditions, as on a newly paved asphalt road. The
2008.50 Kuga 8/2011
slight noise is in no way detrimental and must be

considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a
thorough visual inspection of the vehicle have
been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the
preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition
by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon
as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks

1. 24-80 km/h (15-50 mph): with light acceleration,
a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2. Acceleration/Deceleration: With slow
acceleration and deceleration, a shake is
G37349en

TO MODEL INDEX
100-04-2
100-04-2
Noise, Vibration and Harshness (NVH)

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern is not visually evident, verify the
symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure

Section
Noise, vibration and harshness (NVH) concerns
have become more important as vehicles have
become more sensitive to these vibrations. This
section is designed to aid in identifying these
concerns.
The section provides diagnostic procedures
based on symptom. If the condition occurs at
high speed, for instance, the most likely place
to start is under Shake and Vibration While
Driving.
The road test procedure will tell how to sort the
conditions into categories and how to tell a
vibration from a shake.
A series of Road Test Quick Checks are
provided to make sure that a cause is either
pinpointed or eliminated.
Name the condition, proceed to the appropriate
section and locate the correct diagnosis. When
the condition is identified, the job is partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step,
while more involved tests and adjustments are
outlined in General Procedures.
Always follow each step exactly and make notes
to recall important findings later.
Customer Interview
The road test and customer interview (if available)
provide information that will help identify the
concern and will provide direction to the correct
starting point for diagnosis.
2008.50 Kuga 8/2011
Identify the Condition

NVH usually occur in four areas:
tires
engine accessories
suspension
driveline
It is important, therefore, that an NVH concern be

isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To assist
in the diagnosis and testing procedure(s), use a
suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure

Non-Axle Noise
The five most common sources of non-axle noise
are exhaust, tires, roof racks, trim panels and
transmission.
Therefore, make sure that none of the following
conditions are the cause of the noise before
proceeding with a driveline teardown and
diagnosis.
In certain conditions, the pitch of the exhaust
may sound very much like gear noise. At other
times, it can be mistaken for a wheel bearing
rumble.
Tires, especially snow tires, can have a high
pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic.
Also, any non-standard tire with an unusual
tread construction may emit a roar or whine
noise.
Trim panels can also cause whistling or whining
noise.
Clunk may be a metallic noise heard when the
automatic transaxle is engaged in "R"
(REVERSE) or "D" (DRIVE) or it may occur
when the throttle is applied or released. It is
caused by backlash somewhere in the driveline.
Bearing rumble sounds like marbles being
tumbled. This condition is usually caused by a
damaged wheel bearing.
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3.
4.
5.
sometimes noticed in the steering wheel/column,

seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to Idle
Boom/Shake/Vibration in the Driveline Noise
and Vibration Symptom Chart.
High Speed: A vibration is felt in the front floor
panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
Engine rpm Sensitive: A vibration is felt
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
Noise and Vibration While Turning: Clicking,
popping or grinding noises may be due to the
following:
worn, damaged or incorrectly installed front
wheel bearing.
damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise
produced. Once the route is established and
2008.50 Kuga 8/2011
consistently used, the road noise variable is

eliminated from the test results.
NOTE: Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions

Check for the noise in the following conditions to
verify the customer concern.
Check for the noise in several temperature
conditions.
Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it
random?
Check the condition of the vehicle age, mileage
and service record.
Interview the customer to find the operating
condition in which the noise will occur. Test the
vehicle based on the detail(s) from the customer
interview.
Follow the power steering operation noise
condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check

Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
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Power assisted steering operating condition
Parking
Driving
Steering central/slightly
off center
Steering at a steering
lock stop
Driving straight ahead
Cornering condition
REFER to NVH
concerns from other
components column A
REFER to NVH
concerns from other
components column B
REFER to NVH
concerns from other
components column C
REFER to NVH
concerns from other
components column D
NVH concerns from other components

NVH concerns from other condition (column A to D)
Noise
Driving Condition
Pedal box knocking
Drive off, stop driving and slow cornering

over uneven roads
Stabilizer bar link

knocking
Drive off, driving and cornering
Engine support insulator knocking
Drive off, driving, acceleration and

deceleration
Air conditioning
knocking
Engine on, activate switch for air conditioning
Suspension knocking
(Subframe, Springs)
Drive off, driving, cornering, acceleration

and deceleration
Constant velocity (CV) Drive off, driving, cornering, acceleration

joint knocking
and deceleration
Washer bottle
Deceleration, acceleration and single

impact
Loose suspension
bolts
All driving conditions
Instrument panel
rattle/squeak
All driving conditions. Engine rpm

dependant
X = Noise will most likely occur in this operating condition.
O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
X
X
Step 2: Check for steering system NVH concerns

according to operation condition described at the
customer interview.
Parking
Steering
central/
slightly off
center
Steering at a
steering lock
stop
2008.50 Kuga 8/2011
Driving
Steering
Steering at a
central/slightly steering lock
off center
stop
Vehicle stationary with engine off

Steering central/
slightly off centre
Steering at a
steering lock stop
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Parking
REFER to
steering
system NVH
concerns
column A
Driving
REFER to
steering
system NVH
concerns
column B
REFER to
steering
system NVH
concerns
column C
Vehicle stationary with engine off
REFER to
REFER to steering REFER to steering
steering system system NVH
system NVH
NVH concerns concerns column E concerns column F
column D
Steering system NVH concerns

Steering System operation condition (column A to F)
Noise
Driving condition
Moan
Parking between lock stops, at engine idle and

also increased engine speed
Whine
Driving, high engine rpm. Must be present from

new
Hiss
a) Parking between lock stops. Must be present

from new
Lock stop impact

knock
b) Holding steering wheel against lock stops. Must

be present from new
a) Parking at lock stop. Must be present from new
X
X
Hammer knock
d) Parking into lock stop and release (vehicle with

hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power
assisted steering (EHPAS))
Hydraulic knock
(clonk)
e) Driving, cobble stones, rough road (clonk). Must

be present from new
Column knock
f) Parking, driving. cobble stones and rough roads
Column rattle
Mainly driving on rough roads
Toc-toc
Steering left and right at high frequency. Must be

present from new
Grinding
When turning steering wheel
Zip
At engine start, low temperatures below -10C

only
X = Noise will most likely occur in this operating condition.
O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating

condition (Column A, B, C, D, E, F), check each
2008.50 Kuga 8/2011
Mechanical knock b) Parking between lock stops, engine OFF. Must

(power assisted
be present from new
steering (PAS) off)
Mechanical Knock c) Parking between lock stops, engine ON (ball
(PAS on)
joint knock)
possible Steering System NVH concern with the

detail symptom charts below.
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Before conducting a vehicle test to identify a NVH
concern carry out the following checks.
1. Check the tire pressures and adjust to
specification, as necessary.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system
temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively
quiet location.
5. The heating - air conditioning (A/C) fan and
radio must be turned off during evaluations and
the windows closed.
Symptom
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle

parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees per
second turning of the steering wheel.
3. Engine speed at 1250 +/- 50 rpm with no
steering action.
4. Engine speed at 1250 +/- 50 rpm with slow 90
degrees per second turning of the steering
wheel.
Possible Sources
Power steering lines.

Power steering system moan
noise A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
Incorrect power steering fluid.
rpm changes. Particularly
annoying at lower engine speed.
Power steering pump.
Power Steering Whine Noise

Test Condition
Listen for steering whine noise with the vehicle

2008.50 Kuga 8/2011
Action
CHECK the routing of the
power steering lines.
CHECK the power steering
line clamps are secure.
CHECK the power steering
lines for clearance from the
vehicle body, front axle crossmember and steering gear.
FLUSH the power steering
system.
REFER to: Power Steering
System Flushing (211-00
Steering System - General
Information, General Procedures).
Pressure pulses from the power
steering pump. Certain amount
of noise level acceptable, not a
safety critical item.

steering action.
degrees turning of the steering wheel.
steering action.
degrees turning of the steering wheel.
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Symptom
Possible Sources
Action
BLEED the power steering
system.
Power steering fluid aeration.

System Vacuum Bleeding (21100 Steering System - General
system.
Power steering system whine

noise a high pitched buzzing
sound like an electric motor or
drill. Whine occurs at the higher
engine rpm, 1500 - 5000 rpm,
frequency does not change if
system is loaded or not loaded.
Incorrect power steering fluid.

system.
Overheated power steering fluid.

Certain amount of noise level

Hydraulic operating condition of
acceptable, not a safety critical
the power steering pump.
item.
Power Steering Hiss Noise

Test Condition
Listen for steering hiss noise with the vehicle

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Symptom
Possible Sources
Action
NOTE: Engine speed at idle

turning the steering wheel slowly Floor seal.
lock to lock.
CHECK the installation and

potential damage of the floor
seal.
Power steering system hiss noise

a high frequency, continuous
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the
steering lock stops, all steering
angles. Noise does not change
with engine rpm and is worse at
high operating temperatures.

item.
Power steering gear valve

design.

Power steering system hydraulic
design.
item.
NOTE: Engine speed at idle

holding the steering wheel
against a steering lock for three
seconds. Do not hold for more
than five seconds.
Power steering pump pressure

Power steering system hiss noise relief valve.
a continuous noise like
escaping air occurs while holding
the steering against a steering
lock stop.
Power Steering Lock Stop Impact Knock

Noise

item.
1. Turn the steering wheel to the left-hand and

right-hand steering locks and listen for the
impact noise.
Test Condition
Listen for steering knock noise with the engine

speed at idle in the following test conditions (noise
also apparent with engine off).
Symptom
Possible Sources
Action
Power steering system knock

noise a heavy loud sound like Power steering gear mechanical Certain amount of noise level
a knock on a door that occurs in noise, metal to metal at end of
parking condition when hitting the steering travel.
item.
lock stop.
Power Steering Mechanical Knock Noise

(PAS off)
Test Condition
1. Turn the steering wheel 90 degrees to the right,

hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left,
hold and then quickly release.
Listen for steering knock noise with the engine off

in the following test conditions (no power assist).
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Symptom
Possible Sources
Action

noise a damped, metallic knock Certain amount of noise level
noise which only occurs at
noise a heavy loud repeating
steering condition with engine off item.
sound like a knock on a door that (very high efforts).
occurs in several driving and
steering conditions.
Tolerances in the steering gear
components.
item.
Power Steering Mechanical Knock Noise

(PAS on)
Test Condition
1. Turn the steering wheel to a steering lock and

return to center quickly.
2. Turn the steering wheel 90 degrees to the left
and then 90 degrees to the right quickly.

speed at idle in the following test conditions (power
assist).
Symptom
noise clear knock noise from
steering gear linkage area.
Possible Sources
Action
REFER to Steering System.
Worn tie-rod ball joints (inner and REFER to: Steering System (21100 Steering System - General
outer ball joints).
Information, Diagnosis and
Testing).
Power Steering Hammer Knock (Hydraulic)

Noise
vehicles with hydraulic power assisted steering

only, not electro-hydraulic power steering).
Test Condition
1. Turn the steering wheel to a steering lock

position and return quickly.

speed at idle in the following test conditions (for
Symptom
Possible Sources
Action

noise loud, metallic sound if
hitting the suspension crossCertain amount of noise level
Hydraulic noise created by presmember with a hammer (sounds
sure impulses.
like metallic noise but is created
item.
by pressure impulse in gear and
return line).
Power Steering Hydraulic Knock/Clonk

Noise
Test Condition
Listen for steering knock/clonk noise in the

following test conditions with the windows closed.
2008.50 Kuga 8/2011
1. Drive over cobbled roads at low speed 10-30

km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm
tall harshness strips at low speed 10-30 km/h
(6-20 mph) both driving straight and with
moderate turning.
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100-04-11

Symptom
Power steering system knock/
clonk noise sounds almost
identical to column knock that
occurs when driving and
cornering over cobbled stones or
rough roads. Noise may appear
to emanate from a location closer
to the floor than that for column
knock (Sounds like metallic noise
but is created by pressure
impulse in gear and return line
similar to a sound like quickly
turning off a water tap).
Possible Sources
Power steering return lines.

item.
High power assist gain of power Certain amount of noise level

steering gear valve (steering gear acceptable, not a safety critical
design - no quality issue).
item.
High power steering pump flow

rate (by design).
Power Steering Column Knock Noise

Test Condition
Listen for steering knock noise in the following test

conditions with windows closed.
Symptom
Possible Sources
Power Steering Toc-Toc Noise

Test Condition
Listen for steering toc-toc noise with the engine

speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.

item.
1. Drive over cobbled stones at low speed 16-40

km/h (10-25 mph) with and without steering
input carefully listening for knock sounds.
2. Drive over straight tar strips, road rails or 25 mm
tall harshness strips at low speed 16-40 km/h
(10-25 mph) both driving straight and with
moderate cornering.
Power steering system column

knock noise a loose sounding
Steering column or steering
rattle or vibration coming from the
column shaft.
column. Noticeable by hearing
and touch.
2008.50 Kuga 8/2011
Action
Action
CHECK the steering column
retaining bolts and attachments
to the steering column and
secure if necessary.
Check steering column and
intermediate shaft for free play or
loose components.
REFER to: Steering System (21100 Steering System - General
Testing).
1. Turn the steering wheel from left to right abruptly

changing direction.
2. Drive the vehicle for low speed parking
manoeuvres constantly changing steering
direction.
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Symptom
Possible Sources
Power steering system toc-toc

noise a metallic noise created
when changing direction of
steering wheel rotation during
parking manoeuvre or at standstill.
Steering gear (design tolerance

in steering rack).
Power Steering Grinding Noise

Test Condition
Listen for steering grinding noise with the engine

speed at idle and the vehicle parked, automatic
2008.50 Kuga 8/2011
Action

item.
transmission in "P" (PARK) or manual transmission

in neutral and the windows closed.
1. Slowly turn the steering wheel from lock to lock.
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
from lock to lock.
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Symptom
Possible Sources
Action

Steering wheel to shroud interferacceptable, not a safety critical
ence.
item.
Steering column bearing.
Power steering system grinding
noise an abrasive noise (like
sand paper rubbing against
wood) occurs between moving
components such as steering
wheel and the steering column
shroud.
Foreign material in contact with

the steering column shaft.

item.
CHECK if floor covering is
obstructing the steering gear
pinion.
CHECK the installation of the
floor seal.
CHECK the clockspring and
secure if necessary.
Clockspring.
REFER to: Clockspring (501-20

Supplemental Restraint
System, Removal and Installation).
Power Steering Zip Noise

Symptom
Possible Sources
High viscosity of power steering

Power steering system zip noise
fluid at low temperature.
occurs when hydraulic fluid
does not flow freely through the
power steering pump supply hose
from steering fluid reservoir to
power steering pump causing
Aeration of the power steering
cavitation at the pump. Zip is
fluid.
primarily a cold weather start-up
phenomenon (below -10C).
Action
item.
BLEED the power steering
system.
System Vacuum Bleeding (21100 Steering System - General
Driveline Noise and Vibration

Symptom
Possible Sources
Wheel end vibration.

Shake and vibration while driving Engine/transmission.
Tip-in moan
2008.50 Kuga 8/2011
Air cleaner.
Power assisted steering.
Powertrain.
Powertrain/drivetrain mounts.
Exhaust system.
Action
GO to Pinpoint Test A.
GO to Pinpoint Test B.
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Symptom
Idle boom/shake/vibration/
shudder
Possible Sources
Action
Cable(s)/hose(s).
Powertrain/drivetrain mounts.
Exhaust system.
Belt/pulleys.
GO to Pinpoint Test C.
Suspension Noise and Vibration

Symptom
Possible Sources
Action
Wheel end vibration analysis
Suspension.
Wheel bearings.
Non-axle noise
Trim panels.
Air conditioning (A/C) system. GO to Pinpoint Test E.
Accessories.
Pinpoint Tests
GO to Pinpoint Test D.
steps necessary to correct the condition. Then

check the operation of the system to make sure
the condition has been corrected.
NOTE: These Pinpoint Tests are designed to take

the technician through a step-by-step diagnosis
After verifying that the condition has been
procedure to determine the cause of a condition.
corrected, make sure all components removed
It may not always be necessary to follow the chart
have been installed.
to its conclusion. Carry out only the pinpoint test
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
TEST CONDITIONS
DETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST

1 Carry out the neutral coast test.
Does the vibration disappear during the neutral
coast test?
Yes
GO to A2.
No
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as
necessary.
No
INSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
2008.50 Kuga 8/2011
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PINPOINT TEST B : TIP-IN MOAN
TEST CONDITIONS
B1: CHECK THE AIR CLEANER

1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
Are the components OK?
Yes
GO to B2.
No
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
Is the exhaust system OK?
Yes
GO to B3.
No
REPAIR as necessary. ROAD TEST as
necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to:
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation),
Is the tip-in moan OK?
Yes
REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering
System - General Information, Diagnosis
and Testing).
No
GO to B4.
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TEST CONDITIONS
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS

Are the powertrain/drivetrain mounts OK?
Yes
necessary.
No
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
TEST CONDITIONS
C1: CHECK THE CABLE/HOSES

1 Check the engine compartment for any
component that may have a touch condition
between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, acceleration cable.
Are the components OK?
Yes
GO to C2.
No
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
Is the installation and bushings OK?
Yes
GO to C3.
No
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100-04-17

TEST CONDITIONS
C3: CHECK THE EXHAUST SYSTEM

1 Carry out the exhaust system neutralizing
procedure.
Is the exhaust system OK?
Yes
GO to C4.
No
REPAIR as necessary. ROAD TEST as
necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Are the powertrain/drivetrain mounts OK?
Yes
necessary.
No
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS
TEST CONDITIONS
D1: INSPECT THE WHEELS AND TIRES

1 Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
Are the wheels and tires OK?
Yes
GO to D2.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
2008.50 Kuga 8/2011
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100-04-18

TEST CONDITIONS
D2: INSPECT THE WHEEL BEARINGS

1 Inspect the wheel bearings.
Are the wheel bearings OK?
Yes
GO to D3.
No
INSTALL new wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
Is the wheel and tire runout OK?
Yes
Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
PINPOINT TEST E : NON-AXLE NOISE
TEST CONDITIONS
E1: INSPECT THE VEHICLE TRIM

1 Check the radiator grille and trim panels to see
if they are the source of the noise.
Are the vehicle trim components causing the
noise?
Yes
INSTALL new trim components or REPAIR as
No
GO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2 Ignition switch in position II.
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100-04-19

TEST CONDITIONS
3 Check the A/C system components for noise by
turning the A/C system on and off.
Is the A/C system causing the noise?
Yes
INSPECT the A/C system.
REFER to: Climate Control System (412-00
Climate Control System - General Information, Diagnosis and Testing).
No
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas,
deflectors and fog lights.
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR, or INSTALL new
accessories or fasteners as required. ROAD
TEST as necessary.
No
VERIFY the customer concern.
2008.50 Kuga 8/2011
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TO MODEL INDEX
204-00-1
Suspension System - General Information
204-00-1
SECTION 204-00 Suspension System - General

Information
CONTENTS
PAGE

Suspension System............................................................................................................
204-00-2
204-00-2
Symptom Chart................................................................................................................... 204-00-2
Pinpoint Tests..................................................................................................................... 204-00-5
Component Tests................................................................................................................ 204-00-12
GENERAL PROCEDURES
Front Toe Adjustment..................................................................................... (14 117 3)
Rear Toe Adjustment...................................................................................... (15 211 3)
204-00-15
204-00-16

TO MODEL INDEX
204-00-2
204-00-2
Suspension System
Special Tool(s)
Mechanical
Alignment Pins, Subframe
205-316 (15-097A)
Wheel knuckles
Tie-rod ends
Front suspension lower arm ball joints
Front suspension lower arm bushings
15097A
Front strut and spring assemblies

Front and rear stabilizer bar and connecting links
Rear springs

damage.
Visual Inspection Chart
Mechanical
Tire pressure(s)
Rear shock absorbers

Rear suspension lower arms
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Wheel and tires
Symptom Chart
Symptom Chart
Symptom
Drift left or right
Possible Sources
Action
Vehicle attitude incorrect (front Vehicles without load levelling

or rear / left or right is high or
shock absorbers, CHECK for
low).
abnormal loading, spring sag
or non-standard springs.
Vehicles with load levelling
shock absorbers, GO to
Pinpoint Test C.
Steering gear or linkage worn CHECK the steering system.
or damaged.
REFER to: Steering System
(211-00 Steering System General Information,
Diagnosis and Testing).
Brake system.
CHECK the brake system.

REFER to: Brake System (20600 Brake System - General
Testing).
2008.50 Kuga 8/2011
Incorrect front crossmember

alignment.
Using the special tool, CHECK

the front subframe alignment..
Worn front wheel bearings.
CHECK the wheel bearings.
Wheel and tires.
G1080717en

TO MODEL INDEX
Climate Control
412-01-31
412-01-31
REMOVAL AND INSTALLATION
Condenser
General Equipment
Cable Ties
Materials
Name
Compressor Oil - Air
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
1. Refer to: Air Conditioning (A/C) System

Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2.
CAUTION: Make sure that all openings
are sealed. Use new blanking caps.
1. Torque: 5 Nm
2. Torque: 8 Nm
E100847
2008.50 Kuga 8/2011
G1022366en

TO MODEL INDEX
Climate Control
412-01-32
412-01-32

3. Refer to: Lifting (100-02 Jacking and Lifting,
5.
4.
E98184
Vehicles with automatic transmission
E98183
6. General Equipment: Cable Ties
1
2
2
E112626
All vehicles
7. Torque: 5 Nm
2008.50 Kuga 8/2011
G1022366en

TO MODEL INDEX
412-01-33
Climate Control
412-01-33
E99948
8.
1
1
E77215
2008.50 Kuga 8/2011
G1022366en

TO MODEL INDEX
412-01-34
Climate Control
412-01-34

Installation
1. To install, reverse the removal procedure.
2. Coat the O-ring seals on the refrigerant lines.
Material: Compressor Oil - Air Conditioning
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1022366en

TO MODEL INDEX
412-01-35
Climate Control
412-01-35
Clutch and Clutch Field Coil

General Equipment
Puller
Removal
1. Refer to: Air Conditioning (A/C) Compressor 2.5L Duratec (147kW/200PS) - VI5 (412-01
Climate Control, Removal and Installation).
4. NOTE: Note the position of the component

before removal.
2. Torque: 13 Nm
E112212
E112210
3. General Equipment: Puller
Installation
1. NOTE: Make sure that the component is
installed to the position noted before removal.
To install, reverse the removal procedure.
2. Refer to: Air Conditioning (A/C) Clutch Air Gap
Adjustment (412-00 Climate Control System
- General Information, General Procedures).
E112211
2008.50 Kuga 8/2011
G1158272en

TO MODEL INDEX
412-01-36
Climate Control
412-01-36
Pollen Filter RHD

Removal
4.
1.
x3
E101638
E51159
Installation
2.
E101552
3.
E101637
2008.50 Kuga 8/2011
G1066764en

TO MODEL INDEX
Climate Control
412-01-37
412-01-37
Blower Motor RHD(34 374 0)

Special Tool(s)
412-131
Remover/Installer, Blower
Engine
3. Refer to: Steering Column (211-04 Steering

Column, Removal and Installation).
4. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
5.
E42948
Removal
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2. Torque: 25 Nm
E101389
E102293
6. Torque: 25 Nm
2008.50 Kuga 8/2011
G1065500en

TO MODEL INDEX
412-01-38
Climate Control
412-01-38
E101553
7.
8.
E101552
E51159
9.
E101579
2008.50 Kuga 8/2011
G1065500en

TO MODEL INDEX
Climate Control
412-01-39
412-01-39

10.
2
1
E101554
11.
CAUTION: Make sure that the blower

motor and fan assembly is placed on
the bench with the fan pointing
upwards.
Special Tool(s): 412-131
412-131
E101555
Installation
1. NOTE: The component can only be installed in
1 position.
2008.50 Kuga 8/2011
G1065500en

TO MODEL INDEX
Climate Control
412-01-40
412-01-40
Blower Motor Resistor Vehicles With: Manual Temperature

Control, RHD(34 382 0)
Installation
Removal

2.
E102293
3.
x2
E101666
2008.50 Kuga 8/2011
G1065567en

TO MODEL INDEX
Climate Control
412-01-41
412-01-41
Blower Motor Resistor Vehicles With: Dual Automatic

Temperature Control(34 382 0)
Removal
1. Refer to: In-Vehicle Crossbeam (501-12
Instrument Panel and Console, Removal and
Installation).
2.
x2
E82113
Installation
2008.50 Kuga 8/2011
G1072295en

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412-01-44
Climate Control
412-01-44

6.

are sealed.
Torque: 25 Nm
E100719
7.
E100720
Installation
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1065508en

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412-01-50
Climate Control
412-01-50

16.
18.
17. 1. If equipped.
19.
WARNING: Be prepared to collect

escaping fluid.
General Equipment: Air Body Saw
2008.50 Kuga 8/2011

E101424
E101425
E101621
G1065510en
412-01-51

TO MODEL INDEX
Climate Control
412-01-51
Installation
1.
2008.50 Kuga 8/2011

E75168
G1065510en

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Climate Control
412-01-53
412-01-53
Suction Accumulator
Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
4.


are sealed.
Torque: 8 Nm
2. Remove the right-hand headlamp.

3.
E100787

6.
E100786
2008.50 Kuga 8/2011
G1065541en

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412-01-55
Climate Control
412-01-55

8. Torque: 18 Nm
E100815
Installation
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1065541en

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Climate Control
412-01-58
412-01-58
Low-Pressure Cutoff Switch

Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
1. Refer to: Air Conditioning (A/C) System Health
2. Torque: 2.5 Nm
E100992
Installation
2. Coat the o-ring seals.
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1065543en

TO MODEL INDEX
Climate Control
412-01-59
412-01-59
High-Pressure Cutoff Switch

Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
2. Torque: 8 Nm
E100944
Installation
2. Coat the o-ring seals.
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1065545en

TO MODEL INDEX
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412-01-61
Climate Control
412-01-61

Installation
2008.50 Kuga 8/2011
G1072298en

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Climate Control
412-01-65
412-01-65
Evaporator Core Orifice

Special Tool(s)
Special Tool(s)
412-034-01
Adapter for 412-034
412-027
Disconnect Tool, Spring Lock
Coupling (1/2" blue)
E129004
34001
412-035
Remover, Damaged
Evaporator Core Orifice
412-034
Remover/Installer, Evaporator
Core Orifice
34005
34004
Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal

3.
2008.50 Kuga 8/2011
G1071472en

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Climate Control
412-01-67
412-01-67

Using the special tools, remove the broken fixed
orifice tube.
Special Tool(s): 412-034, 412-035
412-034
412-035
VFV9510034
Installation
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1071472en

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Climate Control
412-01-69
412-01-69

4.

5.

Torque: 25 Nm
412-027
E101071
6.
E101094
2008.50 Kuga 8/2011

Torque: 8 Nm
G1065547en

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412-01-75
Climate Control
412-01-75
In-Vehicle Temperature Sensor

Removal
4.
1.
E112941
E100834
Installation
2.
E95563
3.
2
E99639
2008.50 Kuga 8/2011
G1158232en

TO MODEL INDEX
Climate Control
412-01-76
412-01-76
Ambient Air Temperature Sensor(34 676 0)

Removal
1.
x4
E112925
2.
E112926
Installation
2008.50 Kuga 8/2011
G1158234en

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Climate Control
412-01-78
412-01-78
Footwell Vent/Duct Blend Door Actuator RHD(34 591 0)

Removal
2.
E102293
3.
x3
x2
E101545
Installation
2008.50 Kuga 8/2011
G1065565en

TO MODEL INDEX
Climate Control
412-01-79
412-01-79
Air Inlet Blend Door Actuator(34 606 0)

Removal
2.
E102293
3.
x3
E100655
Installation
2008.50 Kuga 8/2011
G1065557en

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412-01-83
Climate Control
412-01-83

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E100671
Installation
2008.50 Kuga 8/2011
G1065563en

TO MODEL INDEX
412-02-1
Auxiliary Climate Control
412-02-1
SECTION 412-02 Auxiliary Climate Control

CONTENTS
PAGE

Auxiliary Climate Control (Component Location)................................................................
Auxiliary Climate Control (Overview)..................................................................................
Initial start-up of the fuel-fired booster heater.....................................................................
Lockout...............................................................................................................................
Unlocking the control unit...................................................................................................
Auxiliary Climate Control (System Operation and Component Description)......................
System Diagram.................................................................................................................
System Operation...............................................................................................................
Electric Booster Heater...................................................................................................
Fuel-fired heater - function diagram................................................................................
Boost heat mode.............................................................................................................
Programmable fuel fired booster heater.........................................................................
Immediate start-up of the booster heater........................................................................
Programmed start-up of the booster heater....................................................................
Emergency shutoff..........................................................................................................
Component Description......................................................................................................
Electric Booster Heater...................................................................................................
Detailed illustration of fuel-fired heater...........................................................................
Flame sensor..................................................................................................................
Overheat Sensor.............................................................................................................
ECT.................................................................................................................................
Water pump....................................................................................................................
Fuel pump.......................................................................................................................
412-02-2
412-02-4
412-02-4
412-02-4
412-02-4
412-02-5
412-02-5
412-02-12
412-02-12
412-02-12
412-02-13
412-02-13
412-02-13
412-02-13
412-02-14
412-02-14
412-02-14
412-02-14
412-02-16
412-02-16
412-02-16
412-02-16
412-02-16

Auxiliary Coolant Flow Pump..............................................................................................
Electric Booster Heater.......................................................................................................
Fuel Fired Booster Heater 2.5L Duratec (147kW/200PS) - VI5.....................................
Fuel Fired Booster Heater Fuel Pump................................................................................
412-02-17
412-02-18
412-02-21
412-02-25
DISASSEMBLY AND ASSEMBLY

Fuel Fired Booster Heater..................................................................................................
412-02-26

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412-02-3
412-02-3

Programmable fuel fired booster heater
8
E97620
Item
Description
Item
Description
Fuel powered booster heater
Coolant exhaust
Fresh air inlet
Fuel intake
Coolant intake
Holder for the fuel-fired booster heater
Connector for the booster heater
Exhaust System
Coolant Pump
2008.50 Kuga 8/2011
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412-02-4
412-02-4
Auxiliary Climate Control Overview

Initial start-up of the fuel-fired booster
heater
The fuel-fired booster heater needs to be filled
before being taken into operation for the first time.
Activation of the fuel pump for the fuel-fired booster
heater is controlled by the Ford diagnostic unit.
Lockout
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Lockout can be cancelled by switching the booster
heater off then on again, although this may only
be repeated at most 2 times.
Overheating sensor
In the event of overheating (water shortage, poorly
ventilated coolant circuit), the fuel supply to the
booster heater is interrupted and a lockout occurs.
After the cause of the overheating has been
eliminated, the booster heater can be started again
by switching it off and on, if the coolant temperature
is below 70C. If the booster heater overheats ten
times in a row, the control unit will be locked.
Unlocking the control unit

Delete the fault memory of the fuel-fired booster
heater after eliminating the cause of the fault using
the Ford diagnostic unit.
2008.50 Kuga 8/2011
G1066980en

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412-02-5
412-02-5
Auxiliary Climate Control System Operation and Component

Description
System Diagram
VIEW DIAGRAM ON THE NEXT PAGE
2008.50 Kuga 8/2011
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412-02-7
412-02-7

Item
Description
Item
Electric Booster Heater

Refer to Component Description: (page
?)
Generator and Alternator
PCM (powertrain control module)
Coolant temperature sensor (ECT (engine

coolant temperature) sensor)
Refer to Component Description: ECT
(page ?)
instrument cluster
GEM (generic electronic module)
Outside temperature sensor
Climate control system control assembly
2008.50 Kuga 8/2011
Description
G1066982en

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412-02-9
412-02-9

Item
Description
Item

?)
Generator and Alternator
PCM
Coolant temperature sensor (ECT sensor)

Refer to Component Description: ECT
(page ?)
instrument cluster
GEM
Outside temperature sensor
2008.50 Kuga 8/2011
Description
G1066982en

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412-02-12
412-02-12
System Operation
In diesel vehicles which give off little residual heat,
a booster heater is used to heat the passenger
compartment rapidly in the case of low ambient
temperatures.
The electric booster heater electronics activate

three output stages as a function of a pulse width
modulated signal PWM (pulse width modulation)
generated by the GEM. The output stages switch
the three heating elements of the electric booster
heater ON or OFF individually, whereby the heating
periods of the individual elements can overlap. Due
to the variable switch-on duration, continuously
variable temperature control is possible. The overall
heating power of the three heating elements is
linearly proportional to the PWM signal. If the PWM
signal is below 10% or above 95%, the electric
booster heater is not activated.
If the interior temperature has been set to HI, or if

the heater controls have been switched to the
highest setting, the two-zone air conditioning
system sends an "electric booster heater ON"
request signal to the CAN (controller area network)
via the medium speed GEM bus. If a manual air
conditioning system is installed, the signal is
transmitted via a conventional cable connection.
The GEM switches on the electric booster heater
depending on the following parameters:
Engine coolant temperature is below 60 C.
Ambient air temperature is below 10 C.
Sufficient generator capacity is available.
The electric booster heater is switched off when

an engine coolant temperature of 70C or an
ambient air temperature of 20C is exceeded.
Fuel-fired heater - function diagram
1
8V
2
11
12
3
11
12
05
30 42 48 54
68
105
120
20
120
10
E97767
2008.50 Kuga 8/2011
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412-02-13
412-02-13

Item
Description
Item
Description
Glow plug
Fuel-fired heater off
Combustion Air Blower
Blower motor on
Fuel pump
Flame detection
Fuel-fired heater on
10
Blower motor off
Fuel-fired heater - large regulating step
11
Large regulating step
Fuel-fired heater - small regulating step
12
Small regulating step
Boost heat mode

When the engine is running, the booster heater
helps the engine to heat the passenger
compartment at low ambient temperatures.
When the coolant temperature reaches 30 C, the
control unit transmits a switch-on signal for the
passenger compartment blower via the CAN bus.
When the coolant temperature drops, the blower
remains on until the temperature reaches 20 C
whereupon it is deactivated.
The fuel tank must be filled to at least 14% for the
system to be switched on. If the fuel level drops
below 8% then the system is switched off.
In boost mode, the fuel fired booster heater is only
switched on if all of the following criteria are met:
Engine speed above 500 rpm. The fuel fired
booster heater is not allowed to start up while
the engine is being cranked; this prevents a
shut-down due to low voltage if the battery
charge is low.
Ambient temperature below 5 C.
Fuel level above 14% of total capacity.
Function is active on the trip computer menu.
One of the following conditions is sufficient to
switch off the booster heater in boost heat mode:
Engine speed below 500 rpm.
Ambient temperature above 11 C.
Function is active on the trip computer menu.
Fuel level below 8% of total capacity.
controlled via a menu in the message centre. The

fuel fired booster heater can be activated and
deactivated via the message centre. (If set to 'Auto'
the system is activated, if set to 'Off' the system is
completely deactivated)
Immediate start-up of the booster

heater
This function enables the fuel-fired booster heater
to be switched on manually when the engine is not
running. This function is activated via the menu on
the driver information system.
The ignition key must be in the II" position before
this menu can be accessed. The timer function of
the booster heater remains active when the ignition
key is in position "0".
After an immediate start-up of the booster heater
it is switched off again after 30 minutes (or if the
fuel level in the fuel tank drops below 8%). The
booster heater stops within 2 minutes of the engine
starting. This leaves enough time to check whether
the switch-on conditions for boost heat mode have
been met, thus preventing the booster heater from
having to switch off and switch back on again. The
heater can be switched off manually at any time
from the menu.
Programmed start-up of the booster

heater
The programmable fuel fired booster heater has

two operating modes:
Instant start
Programmed start
The driver can use a menu to adjust the time at

which the vehicle is to be pre-heated. The following
options are available:
Time setting. One or two times can be
programmed for each day of the week. It is
possible to program days either individually or
together in groups (Mon-Sun/Mon-Sat/Mon-Fri).
Time and data setting
The heater status is displayed on the instrument

cluster display. The parking heater mode is
With the first option, the fuel-fired booster heater

will start repeatedly without needing to be
Programmable fuel fired booster heater
2008.50 Kuga 8/2011
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412-02-14
412-02-14

reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
Ambient air temperature: this message is taken
from the GEM via the CAN bus.
Coolant temperature: this is determined via an
internal sensor in the fuel-fired booster heater.
minutes of the engine starting. This leaves enough

time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
The maximum heating time is 30 minutes at an

outside air temperature of -10 C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 C and +20 C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 C.
Emergency shutoff
The sequence for a programmed start of the

booster heater is as follows:
Two minutes before the start of the maximum
heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
The fuel-fired booster heater calculates the
required heating time and, if necessary, sends
a delay request on the CAN bus.
At the calculated time, the fuel-fired booster
heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
When the coolant temperature reaches +30 C,
the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
Eight minutes after the programmed switch-off
time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
Ten minutes after the switch-off time, the
post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
The booster heater control module deactivates the

system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
After a programmed start-up of the booster heater

it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2
2008.50 Kuga 8/2011
In the event of an accident in which the airbags

are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
Component Description
E97621
The electric booster heater consists of three

individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
G1066982en

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412-02-15
412-02-15
19
12
10
4
11
8
11
14
16
13
17
18
15
E85035
Item
Description
Item
Description
Cooling sleeve cover
ECT
Combustion air blower cover
10
Compression spring
Fuel fired additional heater module
11
'O' Ring
Combustion Air Blower
12
Cooling sleeve
Internal wiring harness - fuel fired

additional heater
Glow plug
13
Gasket
Flame sensor
14
Gasket
Overheat Sensor
15
Heat exchanger
2008.50 Kuga 8/2011
G1066982en

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412-02-16
412-02-16

Item
Description
Item
Description
16
Combustion chamber
18
Combustion blower motor cover
17
'O' Ring
19
Glow plug wiring harness
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Water pump
Lockout can be cancelled by switching the booster

heater off then on again, although this may only
be repeated at most 2 times.
Overheat Sensor
E97646
The overheating sensor enables the fuel-fired

booster heater module to determine the coolant
temperature, protecting the heater from
overheating. The overheating sensor is installed
next to the coolant temperature sensor under a
cover on the top of the fuel-fired heater.
In the event of overheating (lack of water, poorly
ventilated coolant circuit), the fuel supply to the
heater is interrupted and a lockout occurs. After
the cause of the overheating has been eliminated,
the heater can be restarted by switching it off and
on again, if the coolant temperature is below 70C.
If the heater overheats ten times in a row, the
control unit is locked.
The coolant pump is located on the holder for the

fuel-fired heater on the bulkhead in the rear of the
engine compartment. The coolant pump is driven
by a built-in electric motor and circulates the
coolant in the engine cooling system. The delivery
rate for the pump is 820l/h at a delivery pressure
of 0.1 bar.
Fuel pump
ECT
The fuel-fired booster heater module uses the
temperature sensor to determine the coolant
temperature, which it then uses to set the starting
and stopping time. The coolant temperature sensor
is installed next to the overheating sensor under a
cover on the top of the fuel-fired heater.
E97647
The fuel required for the fuel-fired heater is taken

from the fuel system by a fuel pump fitted in the
fuel tank and is delivered to the heater via a fuel
line.
The fuel pump is an electric piston pump which
meters the corresponding fuel volume for the
fuel-fired heater according to a cycle set by the
fuel-fired heater module.
2008.50 Kuga 8/2011
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412-02-17
412-02-17
Auxiliary Coolant Flow Pump

General Equipment
Hose Clamp Remover/Installer
General Equipment
Hose Clamp(s)
Removal
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
2. Refer to: Jacking (100-02 Jacking and Lifting,
3. General Equipment: Hose Clamp(s)
General Equipment: Hose Clamp
Remover/Installer
E112651
Installation
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2008.50 Kuga 8/2011
G1163562en

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412-02-18
412-02-18

Removal
1. Refer to: Floor Console (501-12 Instrument
2. Torque: 9 Nm
3. Refer to: Climate Control Assembly - Vehicles

With: Manual Temperature Control (412-01
Refer to: Climate Control Assembly - Vehicles
With: Automatic Temperature Control (412-01
4. 1. Torque: 10 Nm
2. Torque: 25 Nm
x4
E101619
2008.50 Kuga 8/2011
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5(029$/ $1' ,167$//$7,21

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412-02-20
412-02-20

5.
E101466
Installation
2008.50 Kuga 8/2011
G1074270en

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412-02-21
412-02-21
Fuel Fired Booster Heater 2.5L Duratec (147kW/200PS) - VI5

General Equipment
Hose Clamp(s)
General Equipment
Removal

Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
Operation).
3.
E112641
2008.50 Kuga 8/2011
G1163563en

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412-02-24
412-02-24

7.
E112645
Installation
2. Check the coolant level.
Procedures).
2008.50 Kuga 8/2011
G1163563en

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412-02-25
412-02-25
Fuel Fired Booster Heater Fuel Pump

Removal
1. Refer to: Petrol and Petrol-Ethanol Fuel
Operation).
2. Refer to: Fuel Tank - 2.5L Duratec
(147kW/200PS) - VI5 (310-01 Fuel Tank and
Lines, Removal and Installation).
3. Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E112750
Installation
2008.50 Kuga 8/2011
G1163564en

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412-02-26
412-02-26
Fuel Fired Booster Heater

General Equipment
Flat-bladed screwdriver
Disassembly
4.

2.
E112697
x4
5.
E112695
3.
x4
x4
E112698
6.
E112696
E112699
2008.50 Kuga 8/2011
G1163567en

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412-02-28
412-02-28

13.
15. General Equipment: Flat-bladed screwdriver
x3
E112706
14.
E112708
E112707
Assembly
16. To assemble, reverse the disassembly
procedure.
2008.50 Kuga 8/2011
G1163567en

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413-00-1
Instrument Cluster and Panel Illumination
413-00-1
SECTION 413-00 Instrument Cluster and Panel

Illumination
CONTENTS
PAGE

Instrument Cluster and Panel Illumination..........................................................................
Principles of Operation.......................................................................................................
Instrument Cluster and Dimmable Backlighting ................................................................
413-00-2
413-00-2
413-00-2
413-00-2

TO MODEL INDEX
413-00-2
413-00-2

Refer to Wiring Diagrams Section 413-00, for
schematic and connector information.
Principles of Operation
NOTE: A new instrument cluster must be
configured.
The instrument cluster and panel illumination
consists of dimmable and non-dimmable
illumination. The dimmable panel illumination is
controlled by the panel illumination switch (part of
the headlamp switch), which allows the brightness
level of the backlights to be adjusted dependent
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps
ON position, the intensity of the backlighting can
be adjusted using the panel dimmer switch. The
non dimmable illumination allows for full intensity
dependant on the ignition switch position.
Instrument Cluster and Dimmable

Backlighting
A
navigation system display module

instrument cluster
climate control module
hazard switch
traction control system disable switch
right-hand and left-hand heated front seat
switch(es)

Mechanical
Engine/engine
compartment or
underbody components
Fluid levels
Accessory installation
Electrical
Fuse(s)
Loose or corroded
connector(s)
Instrument cluster
Wiring Harness
Circuit
LED(s)
Bulb(s)

symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
E
E98738
A.
B.
C.
D.
E.
Tachometer
Engine coolant temperature gauge
Fuel gauge
Speedometer
Information display
The dimmable illumination utilizes light emitting

diodes (LEDs) and bulb(s). The following dimmable
components are backlight using LEDs only:
ashtray
cigar lighter
transmission control lever
heater control panel
audio unit
2008.50 Kuga 8/2011
G1054961en

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413-01-1
Instrument Cluster
413-01-1
SECTION 413-01 Instrument Cluster

CONTENTS
PAGE

Instrument Cluster (Overview)............................................................................................
Replacing the instrument cluster........................................................................................
Self-diagnostic mode..........................................................................................................
Instrument Cluster (System Operation and Component Description)................................
System Diagram.................................................................................................................
Instrument Cluster..........................................................................................................
Message center..............................................................................................................
Vehicles with low series instrument cluster.....................................................................
Vehicles with high series instrument cluster...................................................................
413-01-2
413-01-2
413-01-2
413-01-3
413-01-3
413-01-4
413-01-4
413-01-4
413-01-5
413-01-5
413-01-6

Instrument Cluster..............................................................................................................
Configuration of the Instrument Cluster..............................................................................
413-01-7
413-01-7
413-01-7

Instrument Cluster..............................................................................................................
413-01-9

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413-01-2
Instrument Cluster
413-01-2
Instrument Cluster Overview

Replacing the instrument cluster
When installing a new instrument cluster, the Ford
diagnostics device must be connected before
dismantling the instrument cluster, in order to load
the configuration data of the defective instrument
cluster using the "Installation of programmable
modules" routine. In addition, the value on the
odometer of the defective instrument cluster must
be noted, as this is required for configuration of the
new instrument cluster. If the odometer value
cannot be obtained from the instrument cluster
(display failure), the customer should supply the
approximate value.
pressed for more than 3 seconds between tests,

the instrument cluster will exit self-diagnostic
mode.
4. Self-diagnostic mode is deactivated when the
ignition switch is turned to the OFF position or
low battery voltage is detected.
5. If input data to the instrument cluster is missing
or invalid, the tripmeter LCD will display '----'.
6. If the self-diagnostic mode cannot be activated,
test the instrument cluster using the Ford
diagnostic device.
When installing a new instrument cluster, the Ford

diagnostics device must be connected after
installation in order to download the configuration
data of the defective instrument cluster into the
new instrument cluster using the "Installation of
programmable modules" routine, and to configure
the newly installed instrument cluster to the PATS
system.
Self-diagnostic mode
E99006
1. To enter the instrument cluster self-diagnostic

mode, simultaneously press and hold the set
button and turn the ignition switch from position
0 to position II.
2. Entry to self-diagnostic mode is confirmed when
'TEST' is displayed in the odometer's liquid
crystal display (LCD). The instrument cluster
set button must be released within 3 seconds
of TEST being displayed in the tripmeter LCD
(liquid crystal display) display. Otherwise the
system will exit self-diagnostic mode.
3. To navigate through or skip any of the
instrument cluster self-diagnostic mode tests,
press the SET button. If the SET button is
2008.50 Kuga 8/2011
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Instrument Cluster
413-01-4
413-01-4

Item
Description
Item
Description
Instrument Cluster
Steering wheel lock module
Left-hand steering column switch
EHPS (electro-hydraulic power steering)

control module
10
Fuel level sensor
11
Washer water level warning lamp switch
Audio unit
12
Accelerator pedal position sensor
13
RCM (restraints control module)
CPP (clutch pedal position) sensor/BPP

(brake pedal position) sensor
PATS transceiver
14
Lighting control switch
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
Vehicle speed
The PCM receives the necessary signals
from the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
Engine Coolant Temperature
Engine oil pressure.
Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
Ambient temperature
Brake fluid level
Handbrake control
Door latch control
Liftgate latch control
High beam control
Headlamp flasher control
Direction indicator control
The fuel level signal is sent by the two fuel level

sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual
2008.50 Kuga 8/2011
resistors. The instrument cluster converts the raw

fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
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Instrument Cluster
413-01-7
413-01-7
Instrument Cluster
General Equipment
The Ford approved diagnostic tool
Verify the following warning indicators are

working correctly:
Charging.
Turn signals.
Headlamps.


Mechanical
Engine oil filter

Engine oil level
Engine coolant level
Oil pressure switch
Engine coolant level
Coolant thermostat
Engine coolant
temperature (ECT)
sensor
Fuel gauge
Collapsed or
damaged fuel tank
Recirculation hose
Fuel tank filler
pipe/hose
Indicated fuel level
Fuel lines
Fuel tank filler cap
Fuel filter (external
to the fuel tank)
Fuel tank
Door adjustment
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Instrument cluster
Light emitting
diode(s) (LED)(s)

4. NOTE: If none of the following warning
indicators are operating correctly this may
indicate a concern with the central junction
box (CJB). If only one or two of the following
warning indicators are not operating
correctly this may indicate an instrument
cluster concern.
2008.50 Kuga 8/2011
Configuration of the Instrument Cluster

The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on the
Ford approved diagnostic tool.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
NOTE: The odometer value must be recorded from
the original instrument cluster before removal.
If the odometer value cannot be obtained from
the original instrument cluster (display failure)
the customer should supply the approximate
value.
The following features will need to be configured
when a new instrument cluster is installed:
Anti-lock Brake System (ABS)

All wheel drive
Keyless vehicle entry
Electronic power assisted steering
Trip computer
Voice control
Parking aid
Belt minder
Safety belt not fastened
Right hand drive
Overspeed warning
Reverse warning
Turbocharger boost pressure
Speed control
Auxiliary heater
Suspension control
Washer fluid sensor
G1054964en

TO MODEL INDEX
413-01-8
Instrument Cluster
413-01-8
Navigation
Fuel cap release
Engine type
Display language
In addition the new instrument cluster will require

the original odometer value to be entered.
After the installation and configuration of a new
instrument cluster. The passive anti-theft system
(PATS) will require programming by selecting the
Security Access routine on the Ford approved
diagnostic tool.
2008.50 Kuga 8/2011
G1054964en

TO MODEL INDEX
Instrument Cluster
413-01-9
413-01-9
Instrument Cluster
General Equipment
Round-Ended Steel Rule
General Equipment
Ford Diagnostic Equipment
Removal
1. NOTE: This step is only necessary when
installing a new component.
4.
Upload the instrument cluster configuration

information using the Programmable Modules
Installation Routine.
General Equipment: Ford Diagnostic Equipment
Record the odometer value from the original
instrument cluster. If the odometer value cannot
be obtained from the instrument cluster (display
failure), the customer should supply the
approximate odometer value.
E100832
5. General Equipment: Round-Ended Steel Rule
3.
2
1
E101806
2008.50 Kuga 8/2011
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413-06-1
Horn
413-06-1
SECTION 413-06 Horn

CONTENTS
PAGE

Horn....................................................................................................................................
413-06-2
413-06-2
413-06-2

TO MODEL INDEX
413-06-2
Horn
413-06-2
Horn
The horn system consists of a relay, a steering
wheel switch and either one or two horns. The
horn(s) receives voltage from the switched side of
the relay, and the relay switch is controlled on its
ground side by the steering wheel switch.
The horn relay, is located in the Battery junction
box (BJB) and is supplied with a permanent voltage
from the battery.
The steering wheel horn switch shares the steering
wheel clockspring circuit with the air-bag circuit.
Each of these systems work completely
independent of each other.

Electrical
Fuse(s)
Wiring harness
Electrical connector(s)
Horn switch
Horn
Clockspring
Horn relay
BJB

2008.50 Kuga 8/2011
G1055042en

TO MODEL INDEX
413-09-1
Warning Devices
413-09-1
SECTION 413-09 Warning Devices

CONTENTS
PAGE

Warning Devices.................................................................................................................
413-09-2
413-09-2
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating.........................................................................
Preparation.........................................................................................................................
Deactivating/Activating.......................................................................................................
Oil Change Indicator Reset................................................................................................
413-09-3
413-09-3
413-09-3
413-09-4

TO MODEL INDEX
Warning Devices
413-09-2
413-09-2
Warning Devices
Refer to Wiring Diagrams Section 501-20B, for
General Equipment
Ford diagnostic equipment

Mechanical
Safety belt buckle
Electrical
Wiring harness
Electrical
connector(s)
Safety belt buckle
switch
Restraints control
module

symptom and refer to the Ford diagnostic
equipment to diagnose the system.
2008.50 Kuga 8/2011
G1055053en

TO MODEL INDEX
413-09-3
Warning Devices
413-09-3
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating

Preparation
1. Apply the parking brake.
2. Place the transmission selector lever in P
(Park) - vehicles with automatic transmission
or the neutral position - vehicles with manual
transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside
of the vehicle.
Deactivating/Activating
NOTE: Deactivation of the belt minder may also
be carried out using IDS. Follow the instructions
on the screen.
1. Unbuckle the drivers safety belt.
2. Turn the ignition switch to position II. (Do
not start the engine).
3. Wait at least 15 seconds.
4. NOTE: This step must be completed within
60 seconds or the procedure must be
repeated.
Buckle then unbuckle the safety belt nine
times, ending with the safety belt unbuckled.
Release the red unbuckle switch completely
every cycle.
5. The safety belt warning indicator flashes
three times to confirm the belt minder status
change.
6. Turn the ignition switch to position 0. The
deactivation/activation procedure is now
complete.
2008.50 Kuga 8/2011
G167271en

TO MODEL INDEX
413-09-4
Warning Devices
413-09-4
GENERAL PROCEDURES
Oil Change Indicator Reset

1. Turn the ignition key to position II without
cranking the engine.
2. Simultaneously press and hold the accelerator
pedal and the brake pedal for approximately 15
seconds until the oil change reminder indicator
starts to flash or the "Service Oil Reset
Complete" message appears in the information
and message center (if equipped).
3. Release the pedals.
4. Check that the oil change reminder indicator
has turned off or that there is no "Service Oil"
message in the information and message center
(if equipped). If the oil change reminder indicator
is still illuminated or the "Service Oil" message
is still displayed, turn the ignition key to position
0 and repeat the procedure from Step 1. If it has
turned off or the "Service Oil" message has
disappeared, proceed to Step 5.
5. Turn the ignition key to position 0 and leave it
there for at least 2 minutes so that the
powertrain control module (PCM) fully powers
down and updates the non-volatile memory
(NVM) in the PCM.
6. Turn the ignition key to position II without
cranking the engine and check that the oil
change reminder indicator is not illuminated or
that there is no "Service Oil" message displayed.
7. Turn the ignition key to position 0.
2008.50 Kuga 8/2011
G898940en

TO MODEL INDEX
413-13-1
Parking Aid
413-13-1
SECTION 413-13 Parking Aid

CONTENTS
PAGE

Parking Aid (Component Location).....................................................................................
Parking Aid (Overview).......................................................................................................
Parking aid sensors............................................................................................................
Front sensors detection range............................................................................................
Rear sensors detection range............................................................................................
Parking aid camera module................................................................................................
Parking Aid Camera...........................................................................................................
Parking Aid (System Operation and Component Description)...........................................
System Diagram.................................................................................................................
Parking Aid......................................................................................................................
Parking Aid Camera........................................................................................................
Rear parking aid speaker................................................................................................
Parking aid sensors........................................................................................................
Parking aid module.........................................................................................................
Front parking aid speaker...............................................................................................
Parking aid switch...........................................................................................................
Parking aid camera module............................................................................................
Parking Aid Camera........................................................................................................
413-13-2
413-13-5
413-13-5
413-13-5
413-13-6
413-13-6
413-13-6
413-13-7
413-13-7
413-13-12
413-13-12
413-13-13
413-13-15
413-13-15
413-13-15
413-13-15
413-13-16
413-13-16
413-13-16
413-13-16

Parking Aid Vehicles With: Front Parking Aid................................................................
Diagnostic Trouble Codes (DTC) Index..............................................................................
Symptom Chart...................................................................................................................
Pinpoint Tests.....................................................................................................................
Parking Aid Vehicles With: Rear Parking Aid.................................................................
Diagnostic Trouble Codes (DTC) Index..............................................................................
Symptom Chart...................................................................................................................
Pinpoint Tests.....................................................................................................................
413-13-17
413-13-17
413-13-17
413-13-17
413-13-21
413-13-21
413-13-29
413-13-29
413-13-29
413-13-29
413-13-32
413-13-32

Parking Aid Module.............................................................................................................
Parking Aid Camera Module...............................................................................................
Parking Aid Camera............................................................................................................
Front Parking Aid Speaker.................................................................................................
Rear Parking Aid Speaker..................................................................................................
Front Parking Aid Sensor....................................................................................................
Rear Parking Aid Sensor....................................................................................................
413-13-44
413-13-45
413-13-46
413-13-48
413-13-49
413-13-50
413-13-56

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Parking Aid
413-13-3
413-13-3
E97417
E97416
Item
1
Description
Rear parking aid speaker
E97418
Description
Front parking aid speaker (if available)
E97571
Item
3
Item
Description
Parking aid module
2008.50 Kuga 8/2011
Item
Description
Parking aid with LED switch (if available)
G1034397en

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Parking Aid
413-13-5
413-13-5
Parking Aid Overview

Parking aid sensors
CAUTIONS:
Always keep sensors free from dirt, ice and
snow. Do not use any sharp objects to
clean the sensors.
If a high-pressure cleaner is used to wash

the vehicle, the jet must only be aimed at
the sensors briefly at a distance of at least
20 cm.
The parking aid sensors have a separate
decoupling ring, which must be removed before
painting the sensors, and then refitted.
Front sensors detection range

mm
800
60
E97414
2008.50 Kuga 8/2011
G1034398en

TO MODEL INDEX
Parking Aid
413-13-6
413-13-6

Rear sensors detection range
1800
60
mm
E97415
Parking aid camera module

It is not necessary to programme the module after
changing it.
Parking Aid Camera

CAUTIONS:
Always keep the reversing camera free
from dirt, ice and snow. Do not clean with
sharp objects, fat solvents, wax or organic
media. Only use a damp cloth for cleaning.
the reversing camera briefly at a distance
of at least 20 cm.
The reversing camera is sensitive to
pressure. The position and angle of the
camera can be changed with increased
pressure.
It is not necessary to programme the camera after
changing it.
2008.50 Kuga 8/2011
G1034398en

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Parking Aid
413-13-8
413-13-8

Item
Description
Item
Parking aid module

15)
Trailer relay
Rear parking aid sensor

Refer to Component Description: Parking
aid sensors (page 15)
10

11

12


15)
Generic Electronic Module (GEM)
Reverse gear switch
Instrument cluster
ABS sensor assembly
ABS
2008.50 Kuga 8/2011
Description
G1034399en

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Parking Aid
413-13-12
413-13-12

Item
Description
Item
Description

aid sensors (page ?)


10
steering angle sensor
11
Navigation device
System Operation
Parking Aid
WARNING: It is the driver's responsibility
to stay alert during reversing procedures.
The system may fail to detect small
children or animals.
CAUTION: The driver is responsible for
detecting obstacles and judging the
distance between these and the vehicle.
The system may fail to detect some
hanging objects, barriers, narrow obstacles
or painted surfaces, which could damage
the vehicle. Always pay attention when
parking.
The parking aid provides an audible warning to the
driver if there are any obstacles in front of or behind
the vehicle during reverse parking maneuvers.
At low speeds, the parking aid module uses the
parking aid sensors to monitor the area around the
vehicle. If an object is detected within a monitored
area, the parking aid module emits a warning tone
using the respective parking aid speaker.
The rear parking aid is switched on with the
ignition. However, it is only enabled when reverse
gear is selected.
The front and rear parking aid is always switched
off when the ignition is switched on. It is switched
on when reverse gear is selected or if the parking
aid switch in the center console is actuated up to
a speed of 16 km/h.
The parking aid is switched off when the vehicle is
travelling forwards at more than 16 km/h or if the
parking aid switch in the center console is actuated
again.
When the parking aid module activates the system,
the parking aid switch LED is illuminated. If the
vehicle is only fitted with the rear parking aid, there
is no switch.
the echo reflected by an obstacle within the

detection range. The received echo signals are
amplified and converted from an analog signal to
a digital signal by the sensor. The digital signal is
passed to the parking aid module and compared
with pre-programmed data stored in an EEPROM
within the module. The module calculates the
distance to the obstacle by measuring the time
taken between the emitted and received impulses.
If no objects are detected there are no further
warning tones. If an object is detected, repeated
audible tones are emitted from either parking aid
speaker(s) as appropriate. The time delay between
the tones decreases as the distance between the
object and the vehicle decreases, until at
approximately 250 mm (10 inches), the audible
tone becomes continuous.
If the distance between the obstacle and the
vehicle does not decrease, the warning tone
remains constant if the object has been detected
by an internal parking aid sensor. If the obstacle
was detected by an external sensor and the
distance remains unchanged, the warning tone
stops after 3 seconds.
The parking aid module continues to monitor the
distance and will resume the warning tones if a
decrease in distance is detected.
If a trailer is connected to the vehicle, a signal is
sent to the GEM (generic electronic module) via
the trailer relay. This signal is sent to the parking
aid module via the MS CAN bus. When the parking
aid module detects that a trailer is connected to
the vehicle, the rear parking aid sensors are
disabled to prevent constant warnings due to the
close proximity of the trailer.
The parking aid sensors emit a series of ultrasonic

impulses and switch to receiver mode to receive
2008.50 Kuga 8/2011
G1034399en

TO MODEL INDEX
Parking Aid
413-13-13
413-13-13

Parking Aid Camera
For vehicles with a DVD navigation system with a
touch screen, the parking aid camera is supplied
as standard. For vehicles with a standard
navigation system, the camera can be ordered as
an optional extra. The system essentially consists
of a camera with a wide angle lens, a control unit
and a wiring harness which is not integrated in the
vehicle wiring harness.
Vehicle parameters (length, width)

Steering Angle
Vehicle position during the parking maneuver
0,1
On the navigation display screen, the drivers sees

a video image of the area behind the vehicle.
Guides integrated in the camera images by the
parking aid camera module and displayed on the
screen help the driver to find out about the steering
angle, vehicle width, cornering and driving straight
ahead. The system generates these guides using:
0,3
1
E97904
Item
1
Description
Monitoring angle
If the vehicle is also fitted with a rear parking aid,

the distances to the obstacle are displayed as a
3D illustration.
E97905
2008.50 Kuga 8/2011
G1034399en

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413-13-15
Parking Aid
413-13-15
The disc resonates at a frequency of ca. 50kHz,

producing the ultrasonic output. The disc also
receives the reflected echo signal from any objects
within range.
Parking aid module
E89773
The rear parking aid speaker, in addition to its

actual function, is also used for audible indication
of various types of error in the front and rear
parking aids. If the rear parking aid speaker
becomes defective, the front parking aid speaker
will then be used to indicate failure modes.
If an error is detected in the system, a signal tone
is emitted via the speaker for 3 seconds.
Parking aid sensors

CAUTIONS:
Always keep sensors free from dirt, ice and
snow. Do not use any sharp objects to
clean the sensors.
the sensors briefly at a distance of at least
20 cm.
The parking aid sensor consists of the following:
Plastic housing
Aluminum membrane with Piezo disc
Decoupling ring
Printed circuit board (PCB)
E89772
The parking aid module has three connectors which

provide for power, ground and MS CAN bus
connections, as well as the front and rear parking
aid sensors, the parking aid switch and parking aid
speaker.
The parking aid module carries out self-check
routines and when the parking aid is active, checks
the parking aid sensor wiring for short or open
circuits. If a concern is detected, a diagnostic
trouble code (DTC) is stored in a memory in the
parking aid module and the front and rear parking
aid sensors will be disabled until the DTC is cleared
and the ignition cycled. The driver recognizes a
problem through the flashing LED and a shrill
continuous tone, which is emitted for 3 seconds
when the parking aid is activated. If the parking aid
is working properly, short tones are emitted instead
of this continuous tone. DTCs can be read using
the Ford approved diagnostic tool through the data
link connector (DLC).
The parking aid sensor consists of a sensor and a

holder. The holder makes sure that each parking
aid sensor is correctly orientated in relation to its
location in the rear bumper.
The sensors have a 3-pin connector which is
connected to the wiring harness of the front
bumper. This in turn is connected to the main body
wiring harness. Three pins provide for power
supply, ground and signal lines to and from the
parking aid module.
2008.50 Kuga 8/2011
G1034399en

TO MODEL INDEX
413-13-16
Parking Aid
413-13-16

Front parking aid speaker
E89773
Parking aid camera module
E97856
The front parking aid speaker, in addition to its

actual function, is also used for audible indication
of various types of error in the front and rear
parking aids when the rear parking aid speaker
fails.
The data from the optional parking aid is sent to

the module via the Mid Speed CAN data bus. The
signals from the steering angle sensor are sent to
the module via cable. The module is connected to
the navigation device via a video-in/out cable.
Parking aid switch
Parking Aid Camera
E97703
The parking aid switch is a non-locking switch with

an integrated LED for switching the parking aid on
and off. When pressed, the parking aid switch
momentarily connects a ground to the parking aid
module. The LED indicates when the parking aid
is active. The LED is controlled by the parking aid
module.
E97857
The wide angle lens camera is fixed in the handle

strip of the tailgate. It is connected to the parking
aid camera module via a separate line.
The parking aid switch allows the driver to disable

the parking aid when reverse gear is selected or
to activate the parking aid sensors when not in
reverse gear.
If a high tone is emitted for 3 seconds and the lights
in the switch flash, this indicates that there is a
fault. The system is then deactivated.
2008.50 Kuga 8/2011
G1034399en

TO MODEL INDEX
Parking Aid
413-13-17
413-13-17
Parking Aid Vehicles With: Front Parking Aid

General Equipment
The ultrasonic parking aid system activates when
the ignition switch is turned to the RUN and when
the parking brake is OFF. If a front parking aid
switch is fitted the system will be de-activated and
a light emitting diode (LED) will indicate the state
of the system. A lit LED will indicate that the system
is currently deactivated. The parking aid system
will be disabled if a fault is detected in one of the
four front parking aid sensors, the parking aid
speaker or the parking aid module. An error tone
approximately 3 seconds long will be emitted from
the rear parking aid speaker if a fault is detected.
If the rear parking aid speaker is inoperative the
error tone will sound from the front parking aid
speaker.

2. Visually inspect for obvious signs of electrical

damage.
Electrical
Fuse(s)
Wiring harness(s)
Battery junction box (BJB)
Front parking aid sensor(s)
Front parking aid speaker
Parking aid module

before proceeding to the next step
4. If the cause is not visually evident, connect the
Ford diagnostic equipment to the data link
connector (DLC) and select the vehicle system
to be tested from the diagnostic menu.
5. Retrieve the Diagnostic Trouble Code (DTC)s
and refer to the DTC Index.
6. If no DTCs are retrieved or there is no
communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Codes (DTC) Index

DTC Index
DTC
C1711
Description
Possible Source
Action
Front outer left sensor signal Parking aid sensor signal Check the circuit 8-GN9
circuit short to battery
circuit.
(WH/GN) for short to battery.
IF the circuit is OK, INSTALL
Parking aid module.
a new parking aid module.
REFER to: Parking Aid
Module (413-13 Parking
Aid, Removal and Installation).
TEST the system for normal
operation.
C1712
Front outer left sensor signal Parking aid sensor signal GO to Pinpoint Test C.
circuit open or short to
circuit.
ground
Parking aid sensor.
Parking aid module.
2008.50 Kuga 8/2011
G325369en

TO MODEL INDEX
Parking Aid
413-13-18
413-13-18

DTC
Description
Possible Source
Action
CHECK parking aid sensor
for contamination. IF parking
aid sensor is OK. INSTALL
a new parking aid sensor.
operation.
C1713
Concern with front outer left Front outer left parking aid
parking aid sensor
sensor.
C1714
Front outer right sensor

Parking aid sensor signal CHECK the circuit 8-GN6
(WH) for short to battery. IF
signal circuit short to battery
circuit.
the circuit is OK, INSTALL a
Parking aid module.
new parking aid module.
operation.
C1715
Front outer right sensor

signal circuit open or short
to ground
Parking aid sensor signal GO to Pinpoint Test D.

circuit.
Parking aid sensor.
Parking aid module.
C1716
Concern with front outer right Front outer right parking aid CHECK parking aid sensor
parking aid sensor
sensor.
operation.
C1717
Front inner left sensor signal Parking aid sensor signal CHECK the circuit 8-GN8
(WH/BU) for short to battery.
circuit.
Parking aid module.
operation.
C1718
Front inner left sensor signal Parking aid sensor signal GO to Pinpoint Test E.
circuit.
ground
Parking aid sensor.
Parking aid module.
C1719
Concern with front inner left Front inner left parking aid
parking aid sensor
sensor.
2008.50 Kuga 8/2011

operation.
G325369en

TO MODEL INDEX
Parking Aid
413-13-19
413-13-19

DTC
C5739
Description
Possible Source
Action
Front inner right sensor

(WH/RD) for short to battery.
circuit.
Parking aid module.
operation.
C5740
Front inner right sensor

to ground
C5741
Concern with front inner right Front inner right parking aid CHECK parking aid sensor
parking aid sensor
sensor.
operation.
B1299
Sensor voltage supply short Parking aid sensors voltage GO to Pinpoint Test G.
to ground
supply circuits.
C1744
Parking aid speaker circuit

short to ground
Parking aid sensor signal GO to Pinpoint Test F.

circuit.
Parking aid sensor.
Parking aid module.
Parking aid module.
INSTALL a new parking aid

module.
operation.
C1745

short to battery
Parking aid module.

module.
operation.
B1342
RAM Error
Parking aid module.

module.
operation.
2008.50 Kuga 8/2011
G325369en

TO MODEL INDEX
Parking Aid
413-13-20
413-13-20

DTC
B2207
Description
ROM Error
Possible Source
Parking aid module.
Action
module.
operation.
B2477
ROM/EEPROM Error
Parking aid module.

module.
operation.
B2373
LED circuit short to battery
Parking aid sensor signal Check the circuit for short to

battery. IF the circuit is OK,
circuit.
Parking aid switch
module.
operation.
C1748
Parking aid switch input

circuit short to ground.
Parking aid sensor signal Check the parking aid switch

circuit for short to battery. IF
circuit.
Parking aid switch
new parking aid switch. IF
the switch is OK, INSTALL a
operation.
C1920
Parking aid circuit failure.
Parking aid module.

module.
operation.
2008.50 Kuga 8/2011
G325369en

TO MODEL INDEX
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Parking Aid
413-13-29
413-13-29
Parking Aid Vehicles With: Rear Parking Aid

General Equipment
NOTE: The rear parking aid system will be
de-activated when a Ford rear trailer tow module
is attached to the vehicle.
The ultrasonic parking aid system will default to
enabled when the ignition switch is turned to the
RUN position, the system is activated by selecting
reverse gear. The parking aid system will be
disabled if a fault is detected in one of the four rear
parking aid sensors, the parking aid speaker or the
parking aid module. An error tone approximately
3 seconds long will be emitted from the rear parking
aid speaker if a fault is detected. The rear parking
aid speaker will also sound for approximately 3
seconds if an error is detected at each ignition
cycle or if an error is detected when the system
has been activated.

damage.
Electrical
Fuse(s)
Wiring harness(s)
Rear parking aid sensor(s)
Parking aid module

connector (DLC) and select the vehicle system
to be tested from the diagnostic menu.
5. Retrieve the Diagnostic Trouble Code (DTC)s
and refer to the DTC Index.
Diagnostic Trouble Codes (DTC) Index

DTC Index
DTC
C1699
Description
Possible Source
Action
Rear outer left sensor signal Parking aid sensor signal Check the circuit 8-GN22
circuit.
(WH/GN) for short to battery.
Parking aid module.
operation.
C1700
Rear outer left sensor signal Parking aid sensor signal GO to Pinpoint Test C.
circuit.
ground
Parking aid sensor.
Parking aid module.
2008.50 Kuga 8/2011
G295937en

TO MODEL INDEX
Parking Aid
413-13-30
413-13-30

DTC
Description
Possible Source
Action
C1701
Concern with rear outer left Rear outer left parking aid CHECK parking aid sensor
for contamination. IF a
parking aid sensor
sensor.
parking sensor is OK.
sensor. TEST the system for
normal operation.
C1702
Rear outer right sensor

(WH) for short to battery. IF
circuit.
Parking aid module.
operation.
C1703
Rear outer right sensor

to ground
Parking aid sensor signal GO to Pinpoint Test D.

circuit.
Parking aid sensor.
Parking aid module.
C1704
Concern with rear outer right Rear outer right parking

parking aid sensor
aid sensor.
C1705
Rear inner left sensor signal Parking aid sensor signal CHECK the circuit 8-GN21
(WH/BU) for short to battery.
circuit.
Parking aid module.

normal operation.

operation.
C1706
Rear inner left sensor signal Parking aid sensor signal GO to Pinpoint Test E.
circuit.
ground
Parking aid sensor.
Parking aid module.
C1707
Concern with rear inner left Rear inner left parking aid CHECK parking aid sensor
parking aid sensor
sensor.
normal operation.
2008.50 Kuga 8/2011
G295937en

TO MODEL INDEX
Parking Aid
413-13-31
413-13-31

DTC
C1708
Description
Possible Source
Action
Rear inner right sensor

(WH/RD) for short to battery.
circuit.
Parking aid module.
operation.
C1709
Rear inner right sensor

to ground
C1710
Concern with rear inner right Rear inner right parking

parking aid sensor
aid sensor.

normal operation.
B1299
Parking aid sensor voltage

supply short to ground
Parking aid sensors

voltage supply circuits.
GO to Pinpoint Test G.
C1742

short to ground
Parking aid module.

circuit(s).
GO to Pinpoint Test H.
C1743

short to battery
Parking aid module.

circuit(s).
GO to Pinpoint Test I.
B1342
RAM Error
Parking aid module.

module.
Parking aid sensor signal GO to Pinpoint Test F.

circuit.
Parking aid sensor.
Parking aid module.

operation.
B2477
ROM/EEPROM Error
Parking aid module.

module.
operation.
2008.50 Kuga 8/2011
G295937en

TO MODEL INDEX
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2008.50 Kuga 8/2011
G1065573en

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413-13-45
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413-13-45
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E101978
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2008.50 Kuga 8/2011
G1076568en
413-13-46

TO MODEL INDEX
Parking Aid
413-13-46
Parking Aid Camera

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4 mm Drill Bit
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2008.50 Kuga 8/2011
G1065989en
413-13-47

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413-13-47
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2008.50 Kuga 8/2011
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2008.50 Kuga 8/2011
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2008.50 Kuga 8/2011
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2008.50 Kuga 8/2011
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413-13-56
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2008.50 Kuga 8/2011
G1186710en

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Parking Aid
413-13-57
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2008.50 Kuga 8/2011
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2008.50 Kuga 8/2011
G1186710en

TO MODEL INDEX
414-00-1
Charging System - General Information
414-00-1
SECTION 414-00 Charging System - General

Information
CONTENTS
PAGE

Charging System................................................................................................................
Component Tests................................................................................................................
414-00-2
414-00-2
414-00-2

TO MODEL INDEX
414-00-2
414-00-2
Charging System
General Equipment
Midtronics EXP-1050 battery tester
Midtronics GR590-2
ventilation. Failure to follow these

Mechanical

WARNINGS:
Batteries contain sulphuric acid. Avoid
contact with skin, eyes, or clothing. Also,
shield your eyes when working near
batteries to protect against possible
splashing of the acid solution. In case of
acid contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to follow
injury.
gases which can cause personal injury.
Therefore, do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near a
battery, always shield your face and
protect your eyes. Always provide
Normal Charging System Voltages
GenerIgnition Switch
I Circuit
ator B+
Position
Circuit
Electrical
Accessory drive belt Fuse(s)

Generator
Wiring harness(es)
Generator
Electrical
connector(s)
Battery junction box
(BJB)
Battery
Battery cables
Battery monitoring
sensor (BMS)
Charging system
warning indicator
4. Check the operation of the charging system
warning indicator lamp, located in the instrument
cluster. Normal operation is as follows:
Battery
Engine to
battery ground
Charging System
Warning Indicator
Operation
Position 0
0V
10-12V
10-12V
0V
OFF
Position II
0V
10-12V
10-12V
0V
Illuminated
Position II with
the engine
running
13-15V
13-15V
13-15V
0V
OFF

symptom and refer to the Component Tests.
Component Tests
Generator On-Vehicle Tests - No-Load Test
1. Turn off all electrical loads and the ignition
switch.
2008.50 Kuga 8/2011
G1055063en

TO MODEL INDEX
414-00-3
414-00-3

2. Switch the multimeter to the voltage function.
3. Connect the leads of the multimeter across the
battery terminals.
4. Read the voltage (base voltage).
5. Start the engine.
6. Run the engine at 1500 rpm with no electrical
load.
7. Read the voltage. The voltage should be in the
range of 14.1 volts to 15.1 volts. If the voltage
increase is less than 2.5 volts above the base
voltage, carry out the Load Test. If the voltage
increase is greater than 2.5 volts, REFER to the
Ford diagnostic equipment.
Generator On-Vehicle Tests - Load Test

1. With the engine running, turn on the air
conditioning (if equipped), turn the blower motor
to high speed and the headlamps to high beam.
2. Increase the engine speed to 2000 rpm. The
voltage should increase a minimum of 0.5 volts
above the base voltage. If the voltage does not
increase as specified, REFER to the Ford
approved diagnostic tool. If the voltage
increases as specified, the charging system is
charging correctly.
Battery Identification
Z0212058
Item
Description
Cold crank amp (CCA) rating
Reserve capacity (RC) rating (minutes)
Battery voltage
Ford Part number
FINIS code
EN number (European Norm)
2008.50 Kuga 8/2011
Item
Description
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414-00-5
414-00-5

Surface charge removal procedure
Dynamic Response procedure for refined
decisiveness on battery diagnostics
Upgradeable by SD card
Export data feature to send data to infra red
printer
Voltmeter function
Date and time indication with every test
23 languages included within the battery tester
Using the Midtronics EXP-1050 battery

tester
Disconnect the battery ground cable at the
battery negative (-) post. Note: if using this
battery tester on models where the ground cable
is not accessible, the battery does not have to
be removed from the vehicle and may be tested
using the vehicle's 'jump start post' if the battery
tester is set to the correct mode. In this case,
the battery must be disconnected at the positive
(+) post before testing.
Connect the positive red clamp of the Midtronics
EXP-1050 battery tester to the battery positive
(+) post.
Connect the negative black clamp of the
Midtronics EXP-1050 battery tester to the
battery negative (-) post or jump start post as
appropriate.
A poor connection will prevent testing and the
battery tester will display the message CHECK
CONNECTION. If this message appears after you
Battery tester results and required actions

Battery Tester Reading
have correctly reconnected the clamps, clean the

terminals and reconnect.
It is recommended that batteries are always tested
using both battery posts. However, if used in 'jump
start post' mode, the Midtronics EXP-1050 battery
tester will compensate for the extra resistance of
the additional cable.
1. Select BATTERY TEST or START-STOP
BATTERY TEST.
Press the NEXT key to continue.
2. Select the BATTERY LOCATION
UNDER HOOD
UNDER SEAT
OUT OF VEHICLE
3. Select the negative POST TYPE (IN-VEHICLE
ONLY)
BATTERY POST
JUMP START POST
JUMP START POST (Battery Monitoring
Sensor)
4. Select the BATTERY RATING from the drop
down list.
Press the NEXT key to test the battery.
5. If the battery under test is not listed in the drop
down list, it can still be selected with the
MANUAL ENTRY mode. This is item 11 of 11
in the list.
The Midtronics EXP-1050 battery tester will display
the word TESTING while it evaluates the battery.
Action
GOOD BATTERY
Return the battery to service
GOOD - RECHARGE
Fully recharge the battery and return it to service
CHARGE & RETEST
Fully charge the battery and retest (failure to fully

charge the battery before retesting may cause false
readings)
2008.50 Kuga 8/2011
G1055063en

TO MODEL INDEX
414-00-6
414-00-6

Battery Tester Reading
REPLACE BATTERY or BAD CELL BATTERY
Action
WARNING: Do not recharge the battery.
Make sure that the surface charge was removed.
A "REPLACE BATTERY" result could also mean
a poor connection between the battery cables and
the battery. Check the connections are OK and
retest. If the result remains the same, INSTALL a
NEW battery
REFER to: Battery (414-01 Battery, Mounting and
Cables, Removal and Installation).
In addition it is advisable to check the vehicle electrical system. Check that the generator is functioning
correctly and the vehicle does not have an excessive key-off load (in general this should be under
20mA after 40 minutes of key off).
Midtronics EXP-1050 Battery Tester Test

Code
At the end of the test, use the arrow keys to scroll
down the screens to see additional information.
One of these is the TEST CODE.
The TEST CODE has 11 digits, for example:
0021U-B88WKX.
Using the Midtronics GR-590-2
The Midtronics GR-590-2 is both a battery charger

and battery tester and automatically removes the
surface charge as part of the normal operating
procedure.
The Midtronics GR-590-2 can be used on a battery
in-vehicle or out-of-vehicle.
Disconnect the battery ground cable.
Connect the positive red clamp from the
Midtronics GR-590-2 to the battery positive
terminal.
Connect the negative black clamp from the
Midtronics GR-590-2 to the battery negative
terminal.
Connect the AC power cable to the mains outlet
and switch ON.
Follow the instructions supplied with the
Midtronics GR-590-2 to charge the battery.
To disconnect the Midtronics GR-590-2, reverse
the connection procedure.
The Midtronics GR-590-2 will automatically carry
out a charge cycle before giving the resulting test
code. It will bring the battery into a serviceable
condition and if required can proceed to fully
charge the battery.
Functions on the front panel of the Midtronics
GR-590-2
UP and DOWN button: The UP and DOWN

buttons allow the operator to scroll through
selections on the display and increase or
decrease values.
ENTER button: The ENTER button allows the
operator to accept a selection and continue to
the next step.
E136266
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414-00-7
414-00-7

INFO button: The INFO button allows the
operator to enter the Options menu to access
feature such as Languages, BMC Code, Last
Test Data and Print.
STOP button: The STOP button allows the
operator to abort a charging cycle or go back to
previous steps in the menus.
Midtronics GR-590-2 Test Code

At the end of the test, use the arrow keys to scroll
down the screens to see additional information.
One of these is the TEST CODE.
The TEST CODE has 13 digits, for example:
Y74NH-58R36-ESV.
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414-01-1
Battery, Mounting and Cables
414-01-1
SECTION 414-01 Battery, Mounting and Cables

CONTENTS
PAGE
GENERAL PROCEDURES
Battery Disconnect and Connect........................................................................................
Disconnect..........................................................................................................................
Connect..............................................................................................................................
414-01-2
414-01-2
414-01-3

Battery................................................................................................................................
414-01-4

TO MODEL INDEX
414-01-2
414-01-2
GENERAL PROCEDURES
Battery Disconnect and Connect

Disconnect
3.
WARNINGS:
gases which may cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near
the battery always shield your face and
protect your eyes. Always provide
adequate ventilation. Failure to follow
injury.
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Audio unit key code saving devices must
not be used when working on
supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow this
E103137
CAUTION: Make sure the engine is not

running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: Disconnecting the battery will erase fault
codes, drive values and customer data stored in
the modules.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Refer to: Battery and Battery Charging Health
2. Obtain and record the audio unit keycode and
preset radio frequencies.
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414-01-3
414-01-3
GENERAL PROCEDURES
Connect
1. Torque: 15 Nm
E103138
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414-01-4
414-01-4
Battery
Removal
1. Refer to: Battery and Battery Charging Health
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
Installation
1. Torque:
1 15 Nm
2 10 Nm
3 12 Nm
3.
1
2
1
2
3
E102716
E102716
2008.50 Kuga 8/2011

G1065713en

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414-02-1
Generator and Regulator
414-02-1
SECTION 414-02 Generator and Regulator

CONTENTS
PAGE

Generator............................................................................................................................
Smart Charge system.........................................................................................................
414-02-2
414-02-2

Generator 2.5L Duratec (147kW/200PS) - VI5.......................................... (31 414 0)
414-02-3

TO MODEL INDEX
414-02-2
414-02-2
Generator
General information
The powertrain control module (PCM) controls the

alternator charging voltage. The connection
between the PCM and the generator is made via
the control module subnetwork (LIN) bus.
If the load on the alternator is high, the PCM can
increase the idle speed.
The alternator is temporarily deactivated during
engine starting so that the engine drag moment is
minimized and it is reactivated again after the
starting procedure.
The PCM controls the charge control lamp in the
instrument cluster via the controller area network
(CAN) bus.
Smart Charge system

In addition to the familiar functions, the Smart
Charge system also performs the following
functions:
Automatic deactivation of non-critical high power
electrical consumers when the battery voltage
is low in order to reduce the level of current
drawn.
Automatic activation of non-critical high power
is excessively high in order to protect
components which are sensitive to increased
voltages.
The battery charging current is optimized through
continuous calculation of the battery temperature
and monitoring of the alternator output voltage.
following consumers - in this order and with a gap

of 5 seconds between each:
Electric booster heater (vehicles with diesel
engines)
Heated exterior mirrors
Heated rear window
Heated windscreen
If the battery voltage rises back above the lower
threshold then the GEM re-enables all of the
electrical consumers which were previously
disabled. They then have switched off status and
must be switched back on by the driver.
Electrical consumers are switched on due to
excessively high voltage if the GEM determines
that the battery voltage is above the threshold for
overvoltage and the charge control lamp has been
switched on.
When the threshold is reached the GEM
automatically activates the following consumers in this order and with a gap of 5 seconds between
each:
Heated rear window
Heated exterior mirrors
Electric booster heater (vehicles with diesel
engines)
Blower motor
If the battery voltage drops back below the
threshold then the GEM automatically deactivates
any consumers that were switched on. However,
if they were switched on by the driver before the
automatic activation, they will then be switched on
again in turn with a 5-second time interval.
By receiving the forwarded alternator load signal,

the PCM is given early warning whenever an
electric consumer is switched on or off. This means
that the PCM receives information about imminent
changes in the torque drawn by the alternator. By
evaluating this information the PCM can provide a
higher level of idling stability.
The two remaining functions of the Smart Charge
System are controlled by the GEM.
Electrical consumers are switched off due to low
voltage when the GEM determines (on the basis
of the message received from the PCM on the CAN
bus via the instrument cluster) that the battery
voltage has dropped below the threshold.
When the threshold for low battery voltage is
reached the GEM automatically deactivates the
2008.50 Kuga 8/2011
G964174en

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414-02-4
414-02-4

7. NOTE: Install all the bolts finger tight before
final tightening.
1. Torque: 15 Nm
2. Torque: 25 Nm
1
2
E63590
Installation
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
2008.50 Kuga 8/2011
G1202465en

TO MODEL INDEX
414-05-1
Voltage Converter/Inverter
414-05-1
SECTION 414-05 Voltage Converter/Inverter

CONTENTS
PAGE

Direct Current/Alternating Current (DC/AC) Inverter (Component Location)......................
Direct Current/Alternating Current (DC/AC) Inverter (Overview)........................................
Function indicator...............................................................................................................
Direct Current/Alternating Current (DC/AC) Inverter (System Operation and Component
Description).......................................................................................................................
System Diagram.................................................................................................................
DC/AC converter.............................................................................................................
DC/AC converter.............................................................................................................
AC mains outlet...............................................................................................................
414-05-2
414-05-3
414-05-3
414-05-4
414-05-4
414-05-4
414-05-4
414-05-5
414-05-5
414-05-5

Direct Current/Alternating Current (DC/AC) Inverter..........................................................
414-05-7

TO MODEL INDEX
414-05-2
414-05-2
Direct Current/Alternating Current (DC/AC) Inverter Component

Location
E98863
Item
Description
DC/AC converter
AC mains outlet wiring harness
AC mains outlet
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414-05-3
414-05-3
Direct Current/Alternating Current (DC/AC) Inverter Overview

Function indicator
WARNING: For workshop repairs, it is only
permissible to replace the converter as a
complete unit together with the wiring
harness and the socket. The component
must not be opened, as charged capacitors
inside can still carry dangerously high
residual voltages.
The LED in the socket lights up orange when the
converter is supplying a voltage.
In the event of a fault the system switches off and
indicates the cause of the fault by flashing a trouble
code via the LED in the socket:
1x flash
High temperature
2x flashes
Overload
3x flashes
Internal overvoltage
4x flashes
Internal undervoltage
Continuous flashing
Short circuit to power
If the converter switches off due to high
temperature then it switches back on again
automatically once the temperature has cooled
down sufficiently.
With all of the other faults which are displayed, the
converter can be reset by switching the ignition off
and back on again or by unplugging and reinserting
the consumer in the socket.
If these measures are unsuccessful then there are
no further options for directly influencing the
function yourself.
2008.50 Kuga 8/2011
G1055637en

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414-05-4
414-05-4
Direct Current/Alternating Current (DC/AC) Inverter System

Operation and Component Description
System Diagram
6
4
1
E98885
Item
Description
Item
DC/AC converter
?)
AC mains outlet switch
Battery
Ignition relay
Keylesss vehicle module
AC mains outlet
?)
Description
System Operation
DC/AC converter
In the rear part of the center console there is an
optional 230 V socket instead of the outlet of the
standard 12 V electrical system.
For example, an output of 150 W is sufficient to

run laptops, games consoles and mobile phone
chargers.
In this case a DC/AC converter supplies a

continuous power of 150 W at 230 V/50 Hz. It can
also absorb temporary power peaks of up to 300
W when consumers are switched on.
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G1055639en

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414-05-5
414-05-5
converter deactivates the system if the input

voltage is outside this range.
DC/AC converter
AC mains outlet
2
1
E98879
E98864
The converter operates with a series connection

of two power converter circuits. The primary power
converter here is a push-pull converter. It converts
the 12 V supply from the electrical system of the
vehicle to an intermediate direct current link of
approx. 320 V.
Item
Description
230 V/50 Hz outlet
LED (light emitting diode)
Cover
From this intermediate direct current link, the

downstream full H-bridge circuit generates a
pulse-width modulated output voltage with 230
V/50 Hz.
A controller modulates the pulse width of the
square-wave output voltage and maintains an
effective output voltage of 230 V under varying
load conditions and under different input voltages.
Here, the rising and falling edge of the positive and
negative square wave pulse are controlled
symmetrically to the ideal shape of a sine wave,
which - among other things - also makes a positive
contribution to electromagnetic compatibility.
DC/AC converters which supply a modified square
wave output voltage are referred to as 'Modified
Sine Wave Inverters".
With this type of system there is no need for a
residual current operated device for protection in
the event of accidental contact, as all of the 230 V
lines are double-insulated. Potential-free separation
of the entire 230 V voltage part from the vehicle is
provided (electrical isolation).
2
1
E98865
Item
Description
230 V/50 Hz outlet (for UK vehicles)
LED
Cover
In order to prevent accidents and the risk of

electrical shock, the outlet is protected with a child
safety device and the AC outlet switch.
The output voltage of 230 V/50 Hz is not generated

until the switching voltage is present at terminal 1
of the converter via the AC mains outlet switch.
In order to make the system safer for children, the

safety catches for the 230 V contacts can only be
pushed to one side by pressing a Euro plug evenly
into both of the connector openings.
The converter operates with the ignition switched

on and a vehicle electrical supply of between 11
V and 16 V. Internal voltage monitoring in the
The AC mains outlet switch only activates the

system when a consumer is connected to the
outlet.
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414-05-6
414-05-6

The contacts of the outlet exert a more powerful
grip on the plug so that it does not shake loose on
poor road surfaces. An orange LED lights up to
show that the unit has been activated.
2008.50 Kuga 8/2011
G1055639en

TO MODEL INDEX
414-05-7
414-05-7
Direct Current/Alternating Current (DC/AC) Inverter

Removal
3.
2.
E99743
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5(029$/ $1' ,167$//$7,21
(

(
.XJD
*HQ

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414-05-9
414-05-9

5.
E99746
2008.50 Kuga 8/2011
G1065580en

TO MODEL INDEX
414-05-10
414-05-10

6.
E99747
Installation
2008.50 Kuga 8/2011
G1065580en
415-00-1

TO MODEL INDEX
Information and Entertainment System General Information
415-00-1
SECTION 415-00 Information and Entertainment

System - General Information
CONTENTS
PAGE

Audio System......................................................................................................................
Self-Diagnostic Mode - Low Series Audio Unit...................................................................
Self-Diagnostic Mode - High Series Audio Unit GEN 2......................................................
Cellular Phone....................................................................................................................
Diagnostic Trouble Code (DTC) Index Chart......................................................................
Symptom Chart...................................................................................................................
Pinpoint Tests.....................................................................................................................
415-00-2
415-00-2
415-00-2
415-00-2
415-00-4
415-00-4
415-00-4
415-00-5
415-00-6
415-00-7

TO MODEL INDEX
415-00-2
415-00-2
Audio System
General Equipment

NOTE: If the keycode is entered incorrectly 3 times,
the system will allow the next keycode in 30
minutes. After entering the keycode the 10th time
incorrectly the system will lock out. The component
can only be unlocked by the manufacturer.
Mechanical
Electrical
Audio unit
Antenna
Foreign objects
contacting speaker
Trim poorly
fitted/resonance
Audio control switch
(if equipped)
Compact disc (CD)
changer
Fuse(s)
Wiring harness
Electrical
connector(s)
Audio unit
Audio control switch
(if equipped)
CD changer
Central junction box
(CJB)

symptom and refer to the Self-Diagnostic Mode.
Self-Diagnostic Mode - Low Series

Audio Unit
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode,
switch the audio unit ON. Within four seconds
depress the preset buttons 3 and 6 together.
2. Release the preset buttons 3 and 6 and the
audio unit will enter the Self-Diagnostic Mode.
2008.50 Kuga 8/2011
3. The Self-Diagnostic Mode will automatically stop

after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode
Message Displayed
Circuit Tested
1. 4CH RF low
Right hand front woofer

circuit
2. 4CH RF high
Right hand front

tweeter circuit.
3. 4CH LF low
Left hand front woofer

circuit.
3. 4CH LF High
Left hand front tweeter

circuit.
1. 4CH RR low
Right hand rear woofer

circuit
2. 4CH RR high
Right hand rear tweeter

circuit
3. 4CH LR low
Left hand rear woofer

circuit
3. 4CH LR High
Left hand rear tweeter

circuit.
Seek 87.5 - 108.0
Antenna connection
4. If the cause is not evident after the

Self-Diagnostic Mode, connect the Ford
approved diagnostic tool to the data link
connector (DLC).
Self-Diagnostic Mode - High Series

Audio Unit GEN 2
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode,
switch the audio unit ON. Within four seconds
depress the preset button 3 and 6 together.
2. Release the preset button 3 and 6 and the audio
unit will enter the Self-Diagnostic Mode.
3. The Self-Diagnostic Mode will automatically stop
after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode
Message Displayed
RF speaker 600Hz
Circuit Tested
Right hand front woofer
circuit
G1055068en

TO MODEL INDEX
415-00-3
415-00-3

Message Displayed
Circuit Tested
RF speaker 8kHz
Right hand front

tweeter circuit.
LF speaker 600Hz
Left hand front woofer

circuit.
LF speaker 8kHz
Left hand front tweeter

circuit.
RR speaker 600Hz
Right hand rear woofer

circuit
RR speaker 8kHz
Right hand rear tweeter

circuit
LR speaker 600Hz
Left hand rear woofer

circuit
LR speaker 8kHz
Left hand rear tweeter

circuit.
Seek 87.5 - 108.0
Antenna connection

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TO MODEL INDEX
415-00-4
415-00-4
Cellular Phone
General Equipment
NOTE: Voice control will only operate with the
audio unit and components required switched ON.
Voice Control
The portable support electronics (PSE) module

has a voice control system. The customer will be
able to push the VOICE button on the audio control
switch located on the steering column lower
shroud, this will activate the PSE module and allow
voice control. An audible tone will be heard through
the audio unit speakers after which, a voice
command can then be spoken into the microphone
located in the overhead console.
The incoming calls and voice confirmation can be
heard through the audio system speakers.
When a voice command is spoken into the
microphone it will be sent as a signal to the PSE
module. The signal is then sent from the PSE
module to the relevant components on the
medium-speed controller area network (CAN) bus
network. The component will then convert the
signal back into the original voice command.
The components that the PSE module interacts
with are as follows:
audio unit
navigation system display module
cellular phone
For additional information on the cellular phone
system, REFER to the cellular phone Owner's
Guide.
Bluetooth
An input can be given through the cellular phone

with or without the cellular phone connected to the
handset holder. Providing that the cellular phone
is one of the recommended cellular phones for the
system, is supplied with the Bluetooth technology
and the cellular phone is programmed to the PSE
module.
When selected as active the Bluetooth technology
is a wireless system that interacts with the relevant
2008.50 Kuga 8/2011
component modules through the PSE module. The

general operation of the Bluetooth is similar to the
voice control.
Bluetooth technology cannot transfer the cellular
phone's PHONEBOOK or recent outgoing and
incoming call details to the audio unit or navigation
system display module. If the cellular phone is
placed into the handset holder the PHONEBOOK
data and recent outgoing and incoming call
information will be transferred to the audio unit or
navigation system display module.
For additional information, REFER to the cellular
phone Owner's Guide.

NOTE: Make sure that the cellular phone is
featured on the list of recommended cellular
phones for the system.
Make sure that the PSE module and cellular
phone are configured to each other before
starting a system diagnosis. ENTER the
following PIN number on the cellular phone to
configure the cellular phone to the PSE module:
0000.
Make sure that the MUTE symbol is not
displayed on the audio unit when trying to
operate the cellular phone system. If the MUTE
symbol is displayed, this indicates that the PSE
module requires configuring to the vehicle and
the cellular phone requires programming to the
PSE module. GO to Pinpoint Test C.
1. Verify the customer concern by operating the
system using the customers cellular phone.
damage.
Electrical
Fuse(s)
Wiring harness
Cellular phone
Microphone
PSE module
Audio unit
Instrument cluster
Navigation system display module
G1189085en

TO MODEL INDEX
415-00-5
415-00-5

connector (DLC).
5. SELECT the TOOLBOX menu.
6. SELECT the
ENTERTAINMENT/COMMUNICATION menu.
7. SELECT the SPEECH RECOGNITION

MODULE option and follow the instructions on
the display.
8. Retrieve the diagnostic trouble codes (DTC)s
and refer to the Diagnostic Trouble Code (DTC)
Index Chart.
Diagnostic Trouble Code (DTC) Index Chart

DTC
Description/Condition
Possible Source
Action
B1038
Microphone input circuit

failure
Microphone defect or
short to ground
B1317
Battery voltage high
Battery voltage above

16 volts
REFER to: Charging

System (414-00 Charging System - General
Information, Diagnosis
and Testing).
B1318
Battery voltage low
Battery voltage below 9

volts
REFER to: Charging

System (414-00 Charging System - General
Information, Diagnosis
and Testing).
B1342
PSE module failure
PSE module
INSTALL a new PSE

module. TEST the
system for normal operation.
B1899
Microphone input signal

circuit open
Microphone defect or
not connected
B2272
Microphone bias circuit

failure
No supply to microphone
B2477
Faulty module configuration
PSE module
REFER to the Ford

diagnostic equipment.
2008.50 Kuga 8/2011
G1189085en

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415-00-6
415-00-6

DTC
Description/Condition
Possible Source
Action
U0074
Bluetooth communication failure to cellular

phone
PSE module or cellular

phone
CHECK the cellular

phone Bluetooth function with another application to determine if the
cellular phone is the
concern. If the Bluetooth
function operates
correctly with the other
application, INSTALL a
new PSE module. TEST
the system for normal
operation. If the
Bluetooth function does
not operate with other
application, REFER to
the cellular phone
Owner's Guide.
U2050
No application present
PSE module
INSTALL a new PSE

module. TEST the

Symptom Chart
Symptom
No communication with the
portable support electronics
(PSE) module
Possible Sources
Action
PSE module not configured to GO to Pinpoint Test C.

the vehicle.
Fuse(s).
Circuit(s).
PSE module.
DLC.
REFER to: Communications

Network (418-00 Module
Communications Network,
The audio unit display does not PSE module not configured to GO to Pinpoint Test C.
display PHONE
the vehicle.
Audio unit.
Navigation system display
module.
PSE module.
Instrument cluster.
The cellular phone microphone Circuit(s).
is not operating correctly
Microphone.
PSE module.
2008.50 Kuga 8/2011
CHECK all communication

between the instrument cluster,
audio unit, navigation system
display module and PSE
module. REFER to the Ford
G1189085en

TO MODEL INDEX
415-00-7
415-00-7

Symptom
Reduced sound or no sound
through the speakers
Possible Sources
Action
Audio unit.
PSE module.

between the audio unit and
PSE module. REFER to the
Ford diagnostic equipment.
Circuit(s).
Audio unit.
PSE module.
REFER to the Ford diagnostic

equipment.
The cellular phone information Audio unit.

is not displayed
module.
PSE module.
Instrument cluster.
The voice activated phone
functions are inoperative
Circuit(s).
Cellular Phone.
Audio unit.
module.
PSE module.
Instrument cluster.

Cellular phone is not featured CHECK the make and model

of the cellular phone against
on the list of recommended
those on the list of recomcellular phones for the system
mended cellular phones for the
system.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical

measurements.
NOTE: ENTER the following PIN number on the

cellular phone to configure the cellular phone to
the PSE module: 0000.
PINPOINT TEST A : NO COMMUNICATION WITH THE PORTABLE SUPPORT ELECTRONICS (PSE)
MODULE
TEST CONDITIONS
A1: CHECK FOR VOLTAGE AT THE PSE MODULE

1 Disconnect PSE Module C432.
2008.50 Kuga 8/2011
G1189085en

TO MODEL INDEX

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415-01-1
Information and Entertainment System
415-01-1
SECTION 415-01 Information and Entertainment

System
CONTENTS
PAGE

Audio System (Component Location).................................................................................
Audio System (Overview)...................................................................................................
Keycode entry - vehicle with standard audio system.........................................................
Vehicle Identification Number (VID) - entry - vehicle with standard audio system.............
Self-check routine - vehicles with standard audio system..................................................
Keycode entry - vehicles with upgraded audio system......................................................
Audio System (System Operation and Component Description)........................................
System Diagram.................................................................................................................
In-car entertainment........................................................................................................
Vehicles with standard audio system..............................................................................
Vehicles with upgraded audio system.............................................................................
DAB radio........................................................................................................................
AUX port.........................................................................................................................
Radio remote control......................................................................................................
Antenna systems............................................................................................................
Cellular Phone (Component Location)...............................................................................
Cellular Phone (Overview)..................................................................................................
Software update - control module for mobile electronic auxiliary equipment (variant 1)....
Software update - control module for mobile electronic auxiliary equipment (variants 2
and 3)................................................................................................................................
Cellular Phone (System Operation and Component Description)......................................
System Diagram.................................................................................................................
Overview.........................................................................................................................
Voice Control...................................................................................................................
Control module for mobile electronic auxiliary equipment..............................................
Radio remote control......................................................................................................
USB port/AUX socket.....................................................................................................
415-01-2
415-01-3
415-01-3
415-01-3
415-01-3
415-01-3
415-01-5
415-01-5
415-01-8
415-01-8
415-01-8
415-01-8
415-01-9
415-01-9
415-01-9
415-01-9
415-01-10
415-01-11
415-01-12
415-01-12
415-01-12
415-01-13
415-01-13
415-01-17
415-01-17
415-01-17
415-01-18
415-01-18
415-01-19
415-01-19

Audio Unit...........................................................................................................................
Audio Unit Antenna Vehicles With: Glass Roof Panel...................................................
Audio Unit Antenna Vehicles Without: Glass Roof Panel..............................................
Audio Unit Antenna to Connector Cable Vehicles With: Glass Roof Panel...................
Audio Unit Antenna to Connector Cable Vehicles Without: Glass Roof Panel..............
Connector to Audio Unit Antenna Cable.............................................................................
Compact Disc (CD) Changer..............................................................................................
Portable Support Electronics (PSE) Module.................................................. (33 635 0)
Cellular Phone Microphone................................................................................................
415-01-20
415-01-21
415-01-22
415-01-23
415-01-30
415-01-32
415-01-35
415-01-37
415-01-38

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415-01-3
415-01-3
Audio System Overview

Keycode entry - vehicle with standard
audio system
number plate number can be entered and this

fulfills the security function.
The VIN is programmed ex works. If the unit is
replaced, the VIN is automatically transferred by
the diagnostics system during configuration.
Self-check routine - vehicles with

standard audio system.
The audio unit must be in radio mode before
entering the Self-Diagnostic Mode.
E99206
The keycode is entered via the MENU button and

the arrow buttons. The keycode is then confirmed
with the rotary/pushbutton in the middle of the unit.
To enter the audio unit Self-Diagnostic Mode,

switch the audio unit ON. Press pre-set buttons 3
and 6 simultaneously and then release them again.
Keycode entry - vehicles with upgraded

audio system
Only a limited number of attempts to enter the

correct keycode are allowed. The number of
attempts already made is shown in the display.
Following every subsequent unsuccessful attempt,
an uninterrupted waiting period must be observed
before a further attempt can be made.
The display then shows "WAIT XX" and counts
down to "0", provided the ignition remains switched
on. Once this time has expired, a new attempt can
be made to enter the keycode.
After a certain number of unsuccessful attempts
at entering the keycode, the display will show
"LOCKED" or "SAFE". The customer will now be
unable to switch on the device.
E99207
The station keys are used to enter the keycode.

Station key 5 is used to confirm the keycode.
The authorized Ford dealer can remove the lock

and can make up to three further attempts.
Only a limited number of attempts to enter the

correct keycode are allowed. The number of
attempts already made is shown in the display.
Vehicle Identification Number (VID) entry - vehicle with standard audio

system
After the second unsuccessful attempt, the person

entering the keycode will have to wait for an
uninterrupted period of time before making the next
attempt.
It is often extremely difficult to return stolen audio

units which have been seized by the police to their
owners.
Therefore, many Ford audio units offer the option
of, for example, entering a vehicle identification
number into the unit.
For Ford audio systems, the abbreviation VID is
used to refer to the Vehicle Identification Number.
The VIN (chassis number) or, for instance, the
2008.50 Kuga 8/2011
The display then shows "WAIT XX" and counts

down to "0", provided the ignition remains switched
on. Once this time has expired, a new attempt can
be made to enter the keycode.
After a certain number of unsuccessful attempts
at entering the keycode, the display will show
"LOCKED" or "SAFE". The customer will now be
unable to switch on the device.
G1055645en

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415-01-4
415-01-4

The authorized Ford dealer can remove the lock
and can make up to three further attempts.
2008.50 Kuga 8/2011
G1055645en

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415-01-6
415-01-6

Item
Description
Item
Description
In-car entertainment
AUX port
Genetic electronic module (GEM).
Radio remote control.
instrument cluster
10
FM/AM antenna
ABS
11
Front LH mid/bass speaker
ABS sensor assembly
12
Front RH mid/bass speaker
Rear LH mid/bass range speaker
13
Front LH tweeter
Rear RH mid/bass range speaker
14
Front RH tweeter
2008.50 Kuga 8/2011
G1055647en

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415-01-8
415-01-8

Item
Description
Item
Description
Rear RH tweeter
10
AUX port
instrument cluster
11
ABS
12
FM/AM antenna
ABS sensor assembly
13
Front LH mid/bass speaker
Rear LH mid/bass range speaker
14
Front RH mid/bass speaker
Rear RH mid/bass range speaker
15
Front LH tweeter
Rear LH tweeter
16
Front RH tweeter
System Operation
The audio system is connected to the MS CAN
network and uses an internal amplifier which
directly drives the system speakers. It can only be
operated via the head unit and the radio remote
control. The head unit is connected to the vehicle
on the medium speed CAN bus. This allows the
unit to be interrogated for diagnostic purposes.
Vehicles with standard audio system
The automatic volume control (AVC) adjusts the

audio volume depending on the driving speed. The
audio device receives the necessary signals for
the ABS (anti-lock brake system) wheel sensors
from the instrument cluster on the MS-CAN. As
vehicle speed increases the audio level is adjusted
to compensate for extra road and vehicle noise.
Eight AVC settings are possible.
To choose the setting for automatic volume control,
press the MENU button until the AVC display
appears.
The required adjustment level is determined by the
Infotainment control unit based on the driving
speed signal. The vehicle speed signal is received
over the CAN. The signal is an average of the four
wheel speed sensor signals. Should an invalid
speed signal be received the AVC will not alter the
output volume.
E99206
The standard audio system can only be used via

the head unit, the radio remote control and the
mobile electronic accessories module.
AVC is controlled by the audio amplifier.
2008.50 Kuga 8/2011
G1055647en

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415-01-9
415-01-9

Vehicles with upgraded audio system.
With DAB, there is no overlapping of different

stations.
If the transmission signal is reflected by natural
obstacles or buildings while en route, this
causes interference with FM. With DAB,
however, reception is significantly improved by
this.
Service linking
E99207
The upgraded audio system is available with the

following equipment:
Radio/individual CD player with MP3
Radio/individual CD player with MP3 and
Digital Audio Broadcasting (DAB)
Radio with integrated 6x CD changer with MP3
Radio with integrated 6x CD changer with MP3
and DAB
As soon as the audio device no longer receives

the FM signal in sufficient quality, it automatically
switches to the corresponding DAB transmitter, but
the FM display in the audio device remains active.
When the FM signal becomes available again in
sufficient quality, the device automatically switches
back.
AUX port
The audio systems have an auxiliary device input
(AUX IN) which enables the playback of auxiliary
devices such as MiniDisc or MP3 players via the
vehicle's audio system. Sounds is played back
through the vehicle loudspeakers.
DAB radio
DAB is a procedure for digital transmission of radio
programs.
The DAB system was developed in Europe within
the framework of a European development program
and in recent years has been introduced in many
European countries.
The audio signals from up to 12 radio stations are
packaged into a multiplex and bundled into a single
data stream. This is then broadcast via one or more
terrestrial transmitters. This means that individual
transmitters are no longer needed for each radio
station.
In addition to the much larger range of stations that
can be provided to radio listeners through DAB,
there are also several big technical advantages
over the current FM, MW, LW and SW
transmission:
E98650
The following functions can be controlled with the

remote control:
Provided the receiver can receive the signal

from the DAB transmitter, sound reproduction
is guaranteed. There is no fading, as is typical
for AM and mobile FM reception.
Interference, such as crackling noises caused
by high voltage lines, is filtered out by the DAB
receiver.
2008.50 Kuga 8/2011
G1055647en

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415-01-10
415-01-10

Volume adjustment
To increase the volume, press the top rear
button on the remote control.
To lower the volume: Press the bottom rear
button on the remote control.
Search
During radio operation, the station search is
started upwards or downwards within the
frequency band.
During CD operation, this skips to the next
or previous track.
Mode
During radio operation, the next saved station
is called up (if pressed briefly).
During radio operation, to switch wave range
(if pressed and held).
During CD operation, provided a CD changer
is installed, the next CD is played.
Antenna systems
The antenna systems fitted to the vehicle comprise:
AM/FM roof antennal
AM/FM/GPS roof antenna
Roof antenna for digital radio system (vehicles
with DAB radio)
2008.50 Kuga 8/2011
G1055647en

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415-01-12
415-01-12
Cellular Phone Overview

Software update - control module for
mobile electronic auxiliary equipment
(variant 1)
There is a USB port near the central electrical
module. Software updates for the control module
for mobile electronic auxiliary equipment can be
carried out here.
Software update - control module for

mobile electronic auxiliary equipment
(variants 2 and 3)
Software updates for the mobile electronic auxiliary
equipment control module can be performed via
the USB port which is integrated into the center
console.
2008.50 Kuga 8/2011
G1055657en

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415-01-13
415-01-13
Cellular Phone System Operation and Component Description

System Diagram
Version 1
Item
Description
Item
Description
Control module for mobile electronic

auxiliary equipment
415-01-18)
Radio remote control

415-01-19)
Speakers
Audio unit/navigation unit
Microphone.
2008.50 Kuga 8/2011
G1055659en

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415-01-14
415-01-14

Version 2
Item
Description
Item

auxiliary equipment
415-01-18)
Speakers
USB jack
Refer to Component Description: USB
port/AUX socket (page 415-01-19)
Microphone.

415-01-19)
AUX port
2008.50 Kuga 8/2011
Description
G1055659en

TO MODEL INDEX
415-01-15
415-01-15

Version 3
10
MS-CAN
7
1
7
10
E98699
Item
Description
Item
Description

auxiliary equipment
415-01-9)

415-01-19)
Speakers
instrument cluster
Symbian telephone
Audio unit.
USB jack
port/AUX socket (415-01-19)
2008.50 Kuga 8/2011
G1055659en

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415-01-16
415-01-16

Item
8
Description
GPS antenna
Item
Description
Microphone.
10
AUX port
port/AUX socket (415-01-19)
Vehicles equipped with touchscreen DVD navigation system
2008.50 Kuga 8/2011
G1055659en

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415-01-17
415-01-17

Item
Description
Item
Description

auxiliary equipment
415-01-18)
AUX port
Speakers
DVD navigation system with touchscreen
Microphone.

415-01-9)
USB jack
System Operation
Overview
NOTE: In order to prevent discharge of the battery,
if the vehicle is stationary, the Bluetooth mobile
phone and the voice control should only be used
for long periods when the engine is running.
audio system and replay them (audio streaming).

This function will however only be available at a
later date.
NOTE: For certain mobile phones with the Symbian

operating system, a particular file must be installed
to allow full access to the telephone directory via
Bluetooth. This file is referred to as an SIS file and
can be downloaded from the Ford website. You
can obtain more detailed information from your
Ford dealer.
Voice Control
The system allows the driver to use a Bluetooth

equipped cellular phone handset through the
vehicles Information and Entertainment system.
A physical connection (adapter) between the phone
handset and the telephone control module is not
necessary and is therefore not available.
Communications between the two components are
purely Bluetooth. This can limit the available
functions dependant on the handset used.
The mobile phone system comprises the following
components:
Control module for mobile electronic auxiliary
equipment
Microphone.
The control module for the mobile electronic
auxiliary equipment is connected to the
Infotainment system via the CAN bus and the audio
line. This enables audio and control signals to be
passed to and from the auxiliary equipment. The
mobile electronic auxiliary equipment control
module is equipped with a built-in Bluetooth
antenna.
Voice control makes it possible to operate the audio

system without the driver being distracted from the
traffic situation.
When the system is active, if the driver issues a
pre-defined order, the voice recognition system
converts this command into a control signal for the
various multimedia systems. The input can take
the form of dialogues or commands. The driver is
guided through the dialogues by announcements
or questions.
The following systems can be controlled using the
voice recognition system:
Mobile phone
Radio function
CD player/CD changer
EATC (electronic automatic temperature control)
Voice control via the mobile electronic
auxiliary equipment control module is
unnecessary for the DVD navigation system
with touchscreen because this system has
its own integrated voice control function.
Using Bluetooth it is possible to transfer audio files

from Bluetooth compatible storage media to the
2008.50 Kuga 8/2011
G1055659en

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415-01-19
415-01-19

E98650
On vehicles with hands-free kit and voice control,

the radio remote control has a Voice button for
activating the voice control and for picking up and
hanging up a telephone call.
USB port/AUX socket

A USB port and an AUX socket are provided in the
center console for variants 2 and 3. These can be
used to adapt external audio sources such as an
iPod to the on-board audio system. After it is
connected, the iPod is recognized as such and can
be controlled over the audio system. The audio
signal is received via the AUX socket.
2008.50 Kuga 8/2011
G1055659en

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415-01-20
415-01-20
Audio Unit
General Equipment
Audio Unit Removal Tools (GV3301)
General Equipment
Removal
1. NOTE: Make sure that any media is ejected
from the unit.

NOTE: This step is only necessary when

Connect the diagnostic tool and upload the
audio unit configuration information using the
Programmable Modules Installation Routine,
prior to commencing the removal of the audio
unit.
2. General Equipment: Audio Unit Removal Tools
(GV3301)
x4
E102292
Installation
1. NOTE: New units must be configured using the
Programmable Module Installation Routine in
the diagnostic tool.
2008.50 Kuga 8/2011
G1065583en

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415-01-21
415-01-21
Audio Unit Antenna Vehicles With: Glass Roof Panel

Removal
5.
1. On both sides.
Refer to: C-Pillar Trim Panel (501-05 Interior
Trim and Ornamentation, Removal and
Installation).
2. On both sides.
Refer to: D-Pillar Trim Panel (501-05 Interior
Installation).
3.
E93277
4.
E113362
Installation
2
1

1
E113366
2008.50 Kuga 8/2011
G1158242en

TO MODEL INDEX
415-01-22
415-01-22
Audio Unit Antenna Vehicles Without: Glass Roof Panel

Removal
2. Torque: 3 Nm
1.
E113336
E104243
Installation
2008.50 Kuga 8/2011
G1158244en

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415-01-23
415-01-23
Audio Unit Antenna to Connector Cable Vehicles With: Glass

Roof Panel
General Equipment
General Equipment
Hot Glue Gun
Removal
4. All.
1. All.
Refer to: A-Pillar Trim Panel (501-05 Interior
Installation).
2. NOTE: Make sure that new clips are installed.
E93273
3. NOTE: Make sure that new clips are installed.
E87439
5. All.
Installation).
E93274
2008.50 Kuga 8/2011
G1158248en

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415-01-28
415-01-28
E113396
Right-hand drive vehicles

before removal.
General Equipment: Hot Glue Gun
2008.50 Kuga 8/2011
G1158248en

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415-01-29
415-01-29
E113397
Installation
2008.50 Kuga 8/2011
G1158248en

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415-01-30
415-01-30
Audio Unit Antenna to Connector Cable Vehicles Without: Glass

Roof Panel
General Equipment
Draw Cord
Removal
3.
1. Driver side only.

Refer to: A-Pillar Trim Panel (501-05 Interior
Installation).
2. Driver side only.
E71812
E72967
4.
E113252
2008.50 Kuga 8/2011
G1158246en

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415-01-31
415-01-31

5. Torque: 3 Nm
6. 3. Attach a suitable draw cord to the antenna

cable.
General Equipment: Draw Cord
E113254
E113264
Installation
2008.50 Kuga 8/2011
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415-01-35
415-01-35
Compact Disc (CD) Changer

General Equipment
Removal
1. Remove the passenger side front seat.
Refer to: Front Seat (501-10 Seating, Removal
and Installation).

Eject any media from the unit.
3.
E101826
Installation
1.
CAUTION: Make sure that the

horizontal/vertical orientation setting on
the CD changer is in the horizontal
position.
2008.50 Kuga 8/2011
G1065585en

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415-01-36
415-01-36

Position the spring in the correct position (on
both sides) for the vehicle body style.

Remove the CD changer transportation retaining
clips.
E91627
E91630

Configure the CD changer by selecting the
Programmable Module Installation Routine.
2008.50 Kuga 8/2011
G1065585en

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415-01-37
415-01-37
Portable Support Electronics (PSE) Module(33 635 0)

Removal
2.
E102293
3.
E101801
Installation
2008.50 Kuga 8/2011
G1065590en

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417-01-1
Exterior Lighting
417-01-1
SECTION 417-01 Exterior Lighting

CONTENTS
PAGE
PAGE 1 OF 2
SPECIFICATIONS
Specifications......................................................................................................................
Headlamp adjustment.....................................................................................................
417-01-3
417-01-3

Exterior Lighting (Component Location).............................................................................
Exterior Lighting (Overview)...............................................................................................
Front headlamps.................................................................................................................
Conventional Headlamps................................................................................................
Xenon headlamp.............................................................................................................
Headlamp levelling.........................................................................................................
Combined rain sensor/light sensor.....................................................................................
autolamps...........................................................................................................................
Headlamp switch-off delay.................................................................................................
Turn signals........................................................................................................................
Door entry illumination........................................................................................................
Rear Lighting......................................................................................................................
Exterior Lighting (System Operation and Component Description)....................................
System Diagram.................................................................................................................
Headlamp levelling.........................................................................................................
Xenon headlamp.............................................................................................................
Conventional Headlamps................................................................................................
Turn signals....................................................................................................................
Combined rain sensor/light sensor.................................................................................
417-01-4
417-01-5
417-01-5
417-01-5
417-01-5
417-01-6
417-01-7
417-01-7
417-01-7
417-01-7
417-01-7
417-01-8
417-01-9
417-01-9
417-01-10
417-01-10
417-01-10
417-01-10
417-01-11
417-01-11
417-01-11
417-01-11

Fog Lamps..........................................................................................................................
Description of operation......................................................................................................
Inspection and Checking....................................................................................................
Headlamps..........................................................................................................................
Headlamp Leveling.............................................................................................................
Parking, Rear and License Plate Lamps............................................................................
Reversing Lamps................................................................................................................
417-01-12
417-01-12
417-01-13
417-01-15
417-01-15
417-01-16
417-01-17
417-01-17
417-01-18
417-01-19
417-01-19
417-01-20
417-01-21
417-01-21
417-01-22
417-01-2

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Exterior Lighting
417-01-2
PAGE 2 OF 2
Stoplamps...........................................................................................................................
Turn Signal and Hazard Lamps..........................................................................................
417-01-24
417-01-24
417-01-25
417-01-26
417-01-26
417-01-27
GENERAL PROCEDURES
Front Fog Lamp Adjustment...............................................................................................
Headlamp Adjustment........................................................................................................
417-01-29
417-01-30

Headlamp Switch................................................................................................................
Stoplamp Switch.................................................................................................................
Trailer Module.....................................................................................................................
Front Fog Lamp..................................................................................................................
Headlamp Assembly...........................................................................................................
417-01-32
417-01-34
417-01-35
417-01-36
417-01-37

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Exterior Lighting
417-01-3
417-01-3
SPECIFICATIONS
Headlamp adjustment
Component
X value
Headlamp
X = 10 cm/10 m = 034' = 1.0%
Front fog lamp
X = 22 cm/10 m = 116' = 2.2%
2008.50 Kuga 8/2011
G1209238en

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Exterior Lighting
417-01-4
417-01-4
Exterior Lighting Component Location

1
12
13
11
10
E102294
Item
Description
Item
Description
Vehicle level sensors on the front and rear

axles
Door entry illumination (courtesy lamps)
Lighting switch
Side lamp/stoplamp, turn signal lamp
10
Reversing Lamp
Control module for the automatic

headlamp leveling system
Additional high-mounted stoplamp
11
Number plate lamp
Dipped beam headlamp, main beam

headlamp, turn signal lamp, side lamp
Rear fog lamp
12
Fog lamp
Front side turn light
13
Combined rain sensor/light sensor
2008.50 Kuga 8/2011
G1079625en

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Exterior Lighting
417-01-6
417-01-6

The turn signal lamps and side lights are the same
as in conventional headlamps.
Lamp
Bulb
Current draw
Bulb color
Low-beams
D1S
35W
Clear
High beam headlamp
H1
55W
Clear
Turn signal indicator
H21W
21W
Clear
Side lamp
W5W
5W
Clear
Headlamp levelling
Vehicles with conventional headlamps are
equipped with a manual headlamp leveling system.
E101614
An automatic headlamp leveling system is a legal

requirement for vehicles with gas discharge
headlamps.
The automatic headlamp levelling system is a
dynamic system which provides additional benefits
for the driver in terms of improved illumination of
the road due to improved control over the
headlamp beam.
In a static system, the vehicle is only considered
as a stationary object, whereas a dynamic system
also takes into account the dynamic changes to
the inclination of the vehicle whilst driving.
2008.50 Kuga 8/2011
In order to prevent unnecessary changes in the

height of the headlamp beam, the system filters
out surface irregularities and any pitching of the
vehicle under braking and acceleration.
The system is designed to respond to changes in
the inclination of the vehicle caused by load
changes or long-term effects of aerodynamic forces
acting on the vehicle (e.g. due to continuous driving
at high speeds).
Accordingly, the system needs to be set up with
the aid of WDS (Worldwide Diagnostic System)
after any components are replaced or any other
repairs are carried out.
G1079626en

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417-01-7
Exterior Lighting
417-01-7

CAUTIONS:
On vehicles with autolamps, retrofitting
with daytime running lamps is not
permissible, as otherwise, the engine
cannot be stopped when the lighting is
switched on.
On vehicles with autolamps, the daytime
running lamp fuse must not be fitted, as
otherwise, the engine cannot be stopped
when the lighting is switched on.
The combined rain sensor/light sensor is located
behind the interior rear view mirror.
After the last door has been closed, the function

remains active for a further 30 seconds and then
switches off automatically.
When a door or the tailgate is open, the switch-off
time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The switch-off time is adjusted to fixed values at
the factory and can not be re-programmed using
WDS.
Turn signals
autolamps
E101616
E101615
The low beams, side lamps, license plate lamps

as well as the instrument cluster and instrument
panel illumination are switched on automatically if
all the following conditions are met:
Ignition ON
Light switch in the "AUTO" position
Detected ambient light conditions below a stored
threshold value
The turn signals and the warning lamp flash at a

specified frequency and, in the case of failure of a
turn signal, the frequency is doubled.
The turn signal lamps also have a one-touch lane
change function. If the multifunction lever is
pressed just slightly then the relevant turn signal
lamp is actuated 3 times.
Door entry illumination
These are switched on and off by the GEM (generic

electronic module) in accordance with the input
signals from the combined rain/light sensor.
Headlamp switch-off delay

In vehicles with mid to high-end equipment, the
headlamp switch-off delay uses the dipped beam
headlamps and the door entry illumination (if
equipped) to illuminate the vehicle surroundings.
This function is activated by operating the main
beam headlamp lever with the ignition switched
off.
2008.50 Kuga 8/2011
E101617
G1079626en

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417-01-8
Exterior Lighting
417-01-8

On some models, the door entry lamps are installed
in the external mirrors.
Rear Lighting
The door entry lamps should illuminate the ground

in the immediate vicinity of the front doors; they
are equipped with white bulbs, which are installed
in the underside of the mirror.
The door entry illumination is switched on when
one of the doors or the tailgate are opened, or if
an unlocking command is detected and the
following conditions are satisfied:
Vehicle Ignition is off.
Reverse gear is not engaged.
The vehicle speed is below 7 km/h.
The door entry illumination is switched off if one of
the following conditions is satisfied:
The ignition is selected on.
Reverse gear is engaged.
The vehicle speed exceeds 7 km/h.
More than 25 seconds have elapsed since the
tailgate was closed or a central locking
command was determined.
The time set for the battery protection function
for the interior lighting has elapsed.
More than 5 seconds have elapsed since the
doors and the tailgate were closed.
More than 5 seconds have elapsed since a
central locking command was received and the
all doors and the tailgate were closed.
E101618
The rear lamps are each divided into three units.

The reversing lamps are located in the units in the
liftgate.
The outer units in the D-pillars contain the side
lamp as well as the turn signal and stoplamp.
The rear fog lamp is integrated in the lower area
of the bumper.
The high-mounted additional stop lamp is installed
in the middle of the roof spoiler.
Lamp
Bulb
Current draw
Bulb color
Turn signal indicator
PSY19W
19W
Orange
Reversing Lamp
P21W
21W
Clear
Stoplamp/side lamp
W21/5W
21/5W
Clear
Rear fog lamp
P21W
21W
Clear
Additional high-mounted
stoplamp
1 x LED board
1,4W
2008.50 Kuga 8/2011
G1079626en

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([WHULRU /LJKWLQJ

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Exterior Lighting
417-01-10
417-01-10

Item
Description
Item
Description
Headlamp units with turn signal lamp, side

lamp, dipped beam headlamp, main beam
headlamp, positioning motor for headlamp
leveling system
14
GEM
15
Vehicle level sensors
16
Lighting switch
External mirror with side turn signal lamps

and door entry lamp
17
Multifunction lever
18
Hazard flasher switch
10
Door locking units for the front doors
19
11
Fog lamp
20
Reverse gear switch
12
Rear fog lights
21
Keyless Vehicle Module
13
Gas discharge headlamp control module
System Operation
Headlamp levelling
Xenon headlamp
The following components are part of the automatic
headlamp leveling system:
Vehicle level sensors on the front and rear axles
Control module
Actuator motors for headlamp leveling
Accordingly, the system needs to be set up with

the aid of WDS after any components are replaced
or any other repairs are carried out.
The front and rear sensors are Hall sensors which
send a digital signal to the control unit.
Conventional Headlamps
1
2
E102603
Item
Description
Light switch with manual headlamp

leveling system
Headlamp units with positioning motors

for headlamp leveling system
2008.50 Kuga 8/2011
G1079627en

TO MODEL INDEX
417-01-11
Exterior Lighting
417-01-11

The manual headlamp levelling system operates
with an electric motor which is controlled via a
rotary control in the instrument cluster.
Turn signals
1
The GEM switches the direction indicators and the

direction indicator side repeaters on.
The GEM sends a signal to the instrument cluster
via the CAN (controller area network) bus to switch
on the relevant turn indicator and the acoustic
signal.
The signals from the hazard flasher switch and
from the multifunction switch are transmitted to the
GEM via a wiring connection.

The ambient light sensor determines the general
light intensity.
For this purpose, it detects the light over as wide
an angle as possible, without taking the direction
of incidence into account.
3
E40968
Item
Description
Lens
Front light sensor
Ambient light sensor
The front light sensor determines the light intensity

directly in front of the vehicle.
If both the ambient light sensor and the front light
sensor detect a sudden reduction in light intensity
at the same time, then an algorithm-based
calculation is used to determine the fact that the
vehicle has entered a tunnel, a multi-storey car
park or a long underpass.
In this case the request for switching on the
external lighting and the indicator in the instrument
cluster is transmitted to the GEM.
If the vehicle enters into the shade thrown by a
large truck, the two sensors will register different
light intensities.. In this case, the algorithm-based
calculation will not result in the lights being
switched on.
The GEM incorporates a stepped switch-off of the
dipped beam headlamps, side lamps, license plate
illumination and the instrument cluster and
instrument panel illumination. If the ambient light
changes from dark to bright, the GEM first switches
off the low beams. The side lamps, license plate
lamps as well as the instrument cluster and
instrument panel illumination are switched off
approx. 6 seconds after the low beams have been
switched off.
2008.50 Kuga 8/2011
G1079627en

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Exterior Lighting
417-01-12
417-01-12
Fog Lamps
Special Tool(s)
Terminal Probe Kit
29-011A
29011A
Description of operation
A diagnosis of the generic electronic module (GEM)
can be performed with the Ford approved
diagnostic tool. Furthermore, an integrated service
mode enables testing of the input and output
signals without the need for further tools. To enable
activation of service mode:
switch off the ignition,

switch off all other electrical consumers,
apply the handbrake,
shift to neutral
and close the doors.
Activating the service mode
Proceed as follows to activate the service mode:

OPERATE the switch of the heated rear window
and HOLD IT THERE
Turn on the ignition.
RELEASE the switch of the heated rear window
A signal sounds and the turn signal lamps come
on to indicate that service mode has been
successfully activated.
NOTE: If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be activated.
Inputs
SWITCH the windshield wiper switch to the "Off"

position to test the input signals. The following is
a list of the switch signals to be tested, in no
particular order:
Turn signals (right, left, hazard warning lights)

Windshield wiper stage I
Windshield wiper stage II
Windshield washer system
2008.50 Kuga 8/2011
Rear window wiper

Rear window washer system
Doors open/closed
Remote control for central locking with double
locking
Hood open/closed (in vehicles equipped with
an anti-theft alarm system)
Tailgate open/closed
A/C request signal
Heated windscreen (if fitted)
Parking Brake
Brake reservoir fluid level
Speed control system
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release
Ignition switch, terminal 15 (turn key to 0
position, then turn key to II position.)
An acoustic signal sounds and the turn signal

lamps flash to indicate receipt of each input signal
by the generic electronic module.
Test the windshield wiper "intermittent mode" stage
input signal (only vehicles with adjustable
intermittent mode)
The windshield wiper switch must be switched to

"intermittent mode" in order to test the input signal.
The delay times of the input signals can then be
tested by operating the rotary switch. Each change
of the rotary switch position is indicated by an
acoustic signal and illumination of the turn signals.
Output signals
SWITCH the wiper switch to the "intermittent""

position to test the output signals. PRESSING the
heated rear window switch activates the output
signals in the following order:
a.
b.
c.
d.
e.
f.
Turn Indicator Left Hand

Turn Indicator Right Hand
main beam
dipped beam
G1055006en

TO MODEL INDEX
417-01-13
Exterior Lighting
417-01-13

g. Heated rear window
h. Heater blower motor
i. Headlamp washer system (vehicles with gas
discharge headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (if fitted)
l. Alarm horn (vehicles with alarm system)
m. Rear window wiper
n. Rear heated window relay
When the heated rear window switch is pressed
again, the test of the relevant signal is terminated.
once more, the test for the next signal in the list is
started.
Ending the service mode
The GEM automatically ends service mode 20

seconds after the last input or at a driving speed
of over 7 km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
and HOLD IT THERE
SWITCH OFF the ignition
3 signals sound and the turn signal lamps illuminate
to indicate that service mode has ended.
Reset service mode
If, after completion of service mode, some functions

do not operate or do not operate properly, check
the following functions:
Instrument cluster illumination, side lamps and
license plate lamp in autolamps mode
Rear wiper
Headlamp Washers
Electric booster heater
Active anti-theft sounder
Heated windshield
If one or more of the listed functions is not OK, it's
possible that the cause of the fault is due to not
exiting service mode properly. To reactivate the
functions correctly, perform the following steps:
1. SWITCH OFF the ignition
2. SWITCH OFF the switch for the windscreen
wash/wipe system
3. OPERATE the switch of the heated rear window
and HOLD IT THERE
4. Turn on the ignition.
2008.50 Kuga 8/2011
5. RELEASE the heated rear window switch (an

acoustic signal will sound if activation has been
performed correctly)
6. SWITCH the windscreen wash/wipe switch to
the "Intermittent wipe" position
7. OPERATE the heated rear window switch 6
times (the main beam headlamps switch on and
off automatically)
wash/wipe system
and HOLD IT THERE
11. RELEASE the heated rear window switch (three
acoustic signals will sound if activation has been
After completion of the work, check all the
functions.
Inspection and Checking

NOTE: The generic electronic module (GEM) forms
part of the central junction box (CJB).
NOTE: If the instrument cluster is changed, it must
be re-configured. For this purpose, the
vehicle-specific data is read out of the module to
be replaced using the Ford approved diagnostic
tool and is transferred to the new module.
NOTE: Before reading out the vehicle-specific data,
remake all the separated electrical connections in
the vehicle, so that communication between the
module and the Ford approved diagnostic tool is
ensured.
damage.
Visual Inspection
Electrical
Fuse(s)
Lamp(s)
Bulb(s)
Connector(s)
Switch(s)
Wiring harness
3. Resolve any obvious causes or concerns found

during the visual inspection before carrying out
any further tests.
G1055006en

TO MODEL INDEX
417-01-14
Exterior Lighting
417-01-14

2008.50 Kuga 8/2011
G1055006en

TO MODEL INDEX
417-01-15
Exterior Lighting
417-01-15
Headlamps

shift to neutral
A/C request signal

Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release


and HOLD IT THERE
Inputs

particular order:

Rear window wiper
Doors open/closed
locking
2008.50 Kuga 8/2011

intermittent mode)

Output signals

a.
b.
c.
d.
e.
f.
g.
h.
i.

main beam
dipped beam
Heated rear window
Heater blower motor
Headlamp washer system (vehicles with gas
G1056684en

TO MODEL INDEX
417-01-16
Exterior Lighting
417-01-16

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
and HOLD IT THERE
off automatically)
2008.50 Kuga 8/2011

wash/wipe system
and HOLD IT THERE
functions.

ensured.
damage.
Visual Inspection
Mechanical
Headlamp
Electrical
Fuse(s)
Bulb(s)
Lamp(s)
Connector(s).
Switch(s)
Wiring loom

any further tests.
G1056684en

TO MODEL INDEX
Exterior Lighting
417-01-17
417-01-17
Headlamp Leveling
Special Tool(s)
Terminal Probe Kit
29-011A
29011A

shift to neutral

and HOLD IT THERE
Inputs

particular order:

2008.50 Kuga 8/2011
Rear window wiper

Doors open/closed
locking
A/C request signal
Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.
e.
f.

main beam
dipped beam
G1055012en

TO MODEL INDEX
417-01-18
Exterior Lighting
417-01-18

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
and HOLD IT THERE
2008.50 Kuga 8/2011

off automatically)
wash/wipe system
and HOLD IT THERE
functions.

ensured.
(or mechanical) damage.
Visual Inspection
Mechanical
Headlamp
Headlamp adjuster
unit
Electrical
Fuse(s)
Connector(s).
Switch(s)
Wiring loom
Headlamp levelling
sensors
Gas discharge
headlamp control
module

d#uring the visual inspection before carrying out
any further tests.
G1055012en

TO MODEL INDEX
Exterior Lighting
417-01-19
417-01-19
Parking, Rear and License Plate Lamps

Special Tool(s)
Terminal Probe Kit
29-011A
29011A

shift to neutral

and HOLD IT THERE
Inputs

particular order:

2008.50 Kuga 8/2011
Rear window wiper

Doors open/closed
locking
A/C request signal
Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.
e.
f.

main beam
dipped beam
G1055004en

TO MODEL INDEX
417-01-20
Exterior Lighting
417-01-20

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
and HOLD IT THERE
2008.50 Kuga 8/2011

off automatically)
wash/wipe system
and HOLD IT THERE
functions.

remake all the electrical connections which were
separated in the vehicle, so that communication
between the module and the Ford approved
diagnostic tool is ensured.
2. Visually check the following electrical causes
for the concern:
Visual Inspection
Electrical
Fuse(s)
Bulb(s)
Lamp(s)
Connector(s).
Switches
Wiring loom

any further tests.
G1055004en

TO MODEL INDEX
Exterior Lighting
417-01-21
417-01-21
Reversing Lamps
Terminal Probe Kit
29-011A
29011A

shift to neutral

and HOLD IT THERE
Inputs

particular order:
2008.50 Kuga 8/2011

Rear window wiper
Doors open/closed
locking
A/C request signal
Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.

main beam
dipped beam
G1055008en

TO MODEL INDEX
417-01-22
Exterior Lighting
417-01-22

e.
f.
g.
h.
i.
j.
k.
l.
m.
n.

Heated rear window
Heater blower motor
Electric booster heater (if fitted)
Autolamps (if fitted)
Alarm horn (vehicles with alarm system)
Rear window wiper
Rear heated window relay

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
2008.50 Kuga 8/2011

and HOLD IT THERE
off automatically)
wash/wipe system
and HOLD IT THERE
functions.

NOTE: If the generic electronic module (GEM) is
changed, the new one must be reconfigured. For
this purpose, the vehicle-specific data is read out
of the module to be replaced using the Ford
approved diagnostic tool and is transferred to the
new module. REFER to: (418-00 Module
Communications Network)
Communications Network (Description and
Operation),
Communications Network (Description and
Operation).
damage:
NOTE: Ensure correct engagement of the wiring
harness connectors.
G1055008en

TO MODEL INDEX
Exterior Lighting
417-01-23
417-01-23

Visual Inspection
Electrical
Fuse(s)
Lamp(s)
Bulb(s)
Connector(s)
Switches
Relay
Wiring harness

any further tests.
4. If the concern persists after the visual
inspection, PERFORM a fault diagnosis with
the Ford approved diagnostic tool and RECTIFY
any displayed faults in accordance with the
displayed fault description. CHECK the
operation of the system.
2008.50 Kuga 8/2011
G1055008en

TO MODEL INDEX
417-01-24
Exterior Lighting
417-01-24
Stoplamps

shift to neutral

and HOLD IT THERE
Inputs

particular order:

Rear window wiper
Doors open/closed
locking
A/C request signal
2008.50 Kuga 8/2011
Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.

main beam
dipped beam
Heated rear window
Heater blower motor
Rear window wiper
G1056685en

TO MODEL INDEX
417-01-25
Exterior Lighting
417-01-25

started.

and HOLD IT THERE

follows:

functions.

and HOLD IT THERE


Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
and HOLD IT THERE
off automatically)
wash/wipe system
2008.50 Kuga 8/2011

ensured.
damage.
Visual Inspection
Electrical
Fuse(s)
Lamp(s)
Bulb(s)
Connector(s)
Switches
Wiring harness

any further tests.
G1056685en

TO MODEL INDEX
Exterior Lighting
417-01-26
417-01-26
Turn Signal and Hazard Lamps

Terminal Probe Kit
29-011A
29011A

shift to neutral

and HOLD IT THERE
Inputs
SWITCH the windshield wiper switch to the "OFF"

particular order:
2008.50 Kuga 8/2011

Rear window wiper
Doors open/closed
locking
A/C request signal
Parking Brake
Autolamps
Low beam
High beam
Headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.

High beam
Low beam
G1055002en

TO MODEL INDEX
417-01-27
Exterior Lighting
417-01-27

e.
f.
g.
h.
i.
j.
k.
l.
m.
n.

Heated rear window
Heater blower motor
Automatic headlamps (if equipped)
Rear window wiper

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
2008.50 Kuga 8/2011

and HOLD IT THERE
off)
wash/wipe system
and HOLD IT THERE
functions.

NOTE: If the generic electronic module (GEM) is
changed, the new one must be reconfigured. For
this purpose, the vehicle-specific data is read out
of the module to be replaced using the Ford
approved diagnostic tool and is transferred to the
new module.
damage.
Visual Inspection
Electrical
Fuse(s)
Lamp(s)
Connector(s).
Switches
Wiring harness
G1055002en

TO MODEL INDEX
417-01-28
Exterior Lighting
417-01-28

any further tests.
2008.50 Kuga 8/2011
G1055002en

TO MODEL INDEX
417-01-29
Exterior Lighting
417-01-29
GENERAL PROCEDURES
Front Fog Lamp Adjustment

General Equipment
Headlamp Beam Setter
Activation
1. Place the vehicle on a level surface.
2. Ensure that the tire pressures are to
specification and that the vehicle is not
overloaded.
3. Switch on the front fog lamps.
4. Set the measuring screen of the beam setting
equipment to the correct front fog lamp
adjustment setting.
Refer to: Specifications (417-01 Exterior
Lighting, Specifications).
General Equipment: Headlamp Beam Setter
5. Adjust the fog lamp so that the cut-off line
touches the horizontal line.
15
E117218
2008.50 Kuga 8/2011
G1066056en

TO MODEL INDEX
417-01-30
Exterior Lighting
417-01-30
GENERAL PROCEDURES
Headlamp Adjustment
General Equipment
Headlamp Beam Setter
8. Adjust the dipped beams so that the light/dark

boundary touches the horizontal line.
All Vehicles
1. NOTE: Make sure that the tire pressures are to
specification and that the vehicle is unladen.
15
NOTE: Only use a damp cloth to clean the

headlamp lens to avoid any electrostatic
charging.
Ensure that the adjustment is made with the
suspension set up.
2. Place the vehicle on a level surface.
Vehicles with conventional headlamps

3. Repeatedly operate the headlamp leveling
switch and then set it to "0".
Vehicles with adaptive front lighting

4. Use the diagnostic tool to make certain that the
front wheels are in the straight ahead position.
Vehicles with gas discharge headlamps

5. Calibrate the headlamp leveling system using
the diagnostic tool.
All Vehicles
6. NOTE: Always follow the manufacturer's
instructions when handling the equipment.
E117217
9. NOTE: It is acceptable for a stray portion of the

low beam to cross the 15 line.
Adjust the headlamps so that the rising line of
the boundary line lies at the intersection of
Set the measuring screen of the beam setting

equipment to the correct headlamp adjustment
setting.
Refer to: Specifications (417-01 Exterior
Lighting, Specifications).
General Equipment: Headlamp Beam Setter
7. Switch on dipped beam.
2008.50 Kuga 8/2011
G1066055en

TO MODEL INDEX
417-01-31
Exterior Lighting
417-01-31
GENERAL PROCEDURES
horizontal line and the 15 degree line (left-hand
drive vehicle shown).
15
E117216
2008.50 Kuga 8/2011
G1066055en

TO MODEL INDEX
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TO MODEL INDEX
Exterior Lighting
417-01-33
417-01-33

2. Pull out the passenger side air vent.
1
E44737
Item 2 Dipped beam switch

1. Unclip the dipped beam switch through the
driver side air vent cut-out.
E44376
2008.50 Kuga 8/2011
G295560en

TO MODEL INDEX
417-01-34
Exterior Lighting
417-01-34
Stoplamp Switch
Removal
1.
CAUTION: Make sure that the brake

pedal remains in the rest position.
E123773
Installation
1.

2008.50 Kuga 8/2011
G1076278en

TO MODEL INDEX
417-01-35
Exterior Lighting
417-01-35
Trailer Module
Removal
1. Refer to: Loadspace Trim Panel LH (501-05
and Installation).
2.
E122607
Installation
2008.50 Kuga 8/2011
G1158252en

TO MODEL INDEX
417-01-36
Exterior Lighting
417-01-36
Front Fog Lamp

Removal
2.
1.
x2
E115154
E115153
Installation
2. Refer to: Front Fog Lamp Adjustment (417-01
Exterior Lighting, General Procedures).
2008.50 Kuga 8/2011
G1187253en

TO MODEL INDEX
Exterior Lighting
417-01-37
417-01-37
Headlamp Assembly
Removal
1.
E123476
Vehicles with headlamp washers
2.
3.
E123478
2008.50 Kuga 8/2011
G1255597en

TO MODEL INDEX
417-01-38
Exterior Lighting
417-01-38
E123477
Installation
2. Refer to: Headlamp Adjustment (417-01 Exterior
Lighting, General Procedures).
2008.50 Kuga 8/2011
G1255597en

TO MODEL INDEX
417-02-1
Interior Lighting
417-02-1
SECTION 417-02 Interior Lighting

CONTENTS
PAGE

Interior Lighting...................................................................................................................
417-02-2
417-02-2

TO MODEL INDEX
417-02-2
Interior Lighting
417-02-2
Interior Lighting
General Equipment

damage.
Electrical
Fuse(s)
Bulb(s)
Switch(es)
Wiring harness
Interior lamp(s)
Battery saver relay
Door
Central junction box (CJB)

2008.50 Kuga 8/2011
G1055016en

TO MODEL INDEX
417-04-1
Daytime Running Lamps (DRL)
417-04-1
SECTION 417-04 Daytime Running Lamps (DRL)

CONTENTS
PAGE

Daytime Running Lamps (DRL)..........................................................................................
417-04-2
417-04-2
417-04-3

TO MODEL INDEX
417-04-2
417-04-2

Special Tool(s)
Terminal Probe Kit
29-011A
29011A

shift to neutral

and HOLD IT THERE
Inputs

particular order:

2008.50 Kuga 8/2011
Rear window wiper

Doors open/closed
locking
A/C request signal
Parking Brake
Autolamps
dipped beam
main beam
headlamp flasher
Marker Lamps
Reversing lamp
Liftgate release

intermittent mode)

Output signals

a.
b.
c.
d.
e.
f.

main beam
dipped beam
G1055032en

TO MODEL INDEX
417-04-3
417-04-3

started.

follows:
and HOLD IT THERE
Reset service mode

Rear wiper
Headlamp Washers
Heated windshield
wash/wipe system
and HOLD IT THERE
2008.50 Kuga 8/2011

off automatically)
wash/wipe system
and HOLD IT THERE
functions.

ensured.
2. Visually check the following electrical causes
for the concern:
Visual Inspection
Mechanical
Headlamp
Electrical
Fuse(s)
Connector(s).
Switche(s)
Wiring loom

any further tests.
G1055032en

TO MODEL INDEX
418-00-1
Module Communications Network
418-00-1
SECTION 418-00 Module Communications Network

CONTENTS
PAGE

Communications Network (Component Location)..............................................................
Communications Network (Overview)................................................................................
Communications Network (System Operation and Component Description).....................
System Diagram.................................................................................................................
General...........................................................................................................................
Data bus systems...........................................................................................................
ABS.................................................................................................................................
418-00-2
418-00-4
418-00-5
418-00-5
418-00-6
418-00-6
418-00-7
418-00-8
418-00-8

Communications Network...................................................................................................
418-00-9
418-00-9

TO MODEL INDEX
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TO MODEL INDEX
418-00-3
418-00-3

Item
Description
10
Reversing camera module (RVC)
11
Keyless vehicle module (KVM)
12
All-wheel drive control unit
13
RDM - Driver's side
14
RCM (restraints control module)
15
DDM (driver door module)
16
Instrument Cluster
2008.50 Kuga 8/2011
Item
Description
17
High intensity discharge headlamp module

(optional)
18
ABS (anti-lock brake system) module or

electronic stability program module
19
20
The EATC (electronic automatic

temperature control) control module
21
Electrohydraulic power steering module
G1072290en

TO MODEL INDEX
418-00-4
418-00-4
Communications Network Overview

In order to minimize module variations, different
equipment levels and functionalities are
incorporated in the same module. For this reason,
modules must be programmed following
replacement. For this purpose, the vehicle-specific
data are read out of the module to be replaced
using "Install programmable modules" routine in
the Ford diagnostic unit and transferred to the new
module. In the process, it is also possible to replace
older software versions with more up-to-date
versions, for example.
If it was not possible to read out any
vehicle-specific data with the Ford diagnostic unit
before replacing a module (the module to be
replaced does not respond), the data available in
the OASIS system (ASBUILT data) must be
entered manually using the Ford diagnostic unit
when programming the module.
2008.50 Kuga 8/2011
G1030778en

TO MODEL INDEX
418-00-5
418-00-5
Communications Network System Operation and Component

Description
System Diagram
10
C
2
D
1
D
11
12
13
14
15
16
17
18
B
22
21
20
19
23
24
D
D
25
E97186
2008.50 Kuga 8/2011
G1030779en

TO MODEL INDEX
418-00-6
418-00-6

Item
Description
Medium speed CAN (controller area

network) bus (MS-CAN)
High speed CAN bus (HS-CAN)
LIN (local interconnect network) bus
Item
Description
13
Navigation system module - vehicles

equipped with DVD navigation system with
touch screen (not communicating with the
diagnostic unit)
14
Navigation system display - vehicles

equipped with DVD navigation system with
touch screen (not communicating with the
diagnostic unit)
15
Control module for electronic auxiliary

equipment (BVC)
16
RCM
17
Drive Terminating resistors

E
DLC (data link connector)
GEM
Refer to Component Description: ABS
(page ?)
Fuel fired booster heater /programmable

fuel fired booster heater
The EATC control module
18
Instrument Cluster
Reversing camera module (RVC)
19
PCM
Parking aid module (PAM)
20
Fuel additive system module.
DDM
21
Front driver's side switch unit
ABS module or electronic stability program

module
Driver's side RDM
22
Yaw rate sensor/lateral acceleration

sensor
PDM (Passenger Door Module)
23
Headlamp Leveling Module
10
Passenger side RDM
24
11
25
Electrohydraulic power steering module
12
CD changer
System Operation
General
In a communications network (data bus system),
various modules of different systems are connected
to one another via one or several lines.
The data bus system is used exclusively for
transmitting data between the connected modules,
as well as between the connected modules and
the Ford diagnostic unit.
In a data bus system, complete data blocks are
transmitted instead of single on/off pulses. In
addition to the actual information, these data blocks
also contain data regarding the address of the
module to be addressed, the size of the data block
and information for monitoring the content of each
individual data block.
Data bus systems offer various advantages:
2008.50 Kuga 8/2011
Simplified data transmission between the

modules due to a standardized protocol
Fewer sensors and connectors
Improved diagnostic options
Lower costs
The DLC is connected to the various data bus
systems and to the power supply via the standard
16-pin GEM. The signal for the module
programming is also transferred via the DLC.
In a data bus system, if there is a break in one or
both lines or there is a short to ground or to voltage,
then communication between the modules and
with the Ford diagnostic unit is disturbed or is no
longer possible at all.
In order to be able to establish communication with
one another, the modules of the individual systems
G1030779en

TO MODEL INDEX
418-00-7
418-00-7

must use the same language. This language is
called a protocol.
At present, Ford uses three different data bus
systems. Depending upon model and equipment
level, all three data bus systems are used. Each
of these data bus systems has its own protocol.
Data bus systems

ISO 9141 bus
The International Organisation for Standardisation
ISO 9141 bus. This consists of a single wire and
is used exclusively for communication between the
modules and the Ford diagnostic unit. The fault
memories of the various modules are read out via
the ISO 9141 bus.
Local Interconnect Network (LIN) bus
The LIN bus is a standard specifically designed for
cost-effective communication between intelligent
sensors and actuators in vehicles. The LIN control
unit subnet is used in every situation where the
bandwidth and versatility of CAN is not needed.
The LIN specification comprises the LIN protocol,
a standard format for describing a complete LIN
and the interface between an LIN and the
application. An LIN comprises a LIN master and
one or more LIN slaves. The LIN utilizes the
master/slave principle for the purpose of bus
access control. This has the significant advantage
that few resources (CPU performance, ROM, RAM)
are required for bus management in the slave
module. The master is implemented in a control
module or a gateway which has the necessary
resources. All communication is initiated by the
master. Consequently, a message always consists
of a header, which is generated by the master, and
a response from the slave. The data transfer rate
is in the region of up to 20 Kbit/s. The LIN master
knows the time sequence of all data which are to
be transmitted. These data are transmitted by the
corresponding LIN slaves (e.g. ultrasonic sensors)
if they are requested to do so by the LIN master.
LIN is a single-wire bus, i.e. the data are
transmitted in the cable via one wire. Usually the
same cable is also used to provide the supply
voltage. The ground connection of the supply
voltage also acts as the ground connection of the
data transmission. An LIN does not use a
terminating resistor.
Controller Area Network (CAN) bus
This consists of two twisted wires and operates
serially (data is transmitted sequentially). It is used
for communication between the modules
2008.50 Kuga 8/2011
themselves and between the modules and the Ford

diagnostic unit. The modules are connected to the
data bus in parallel. New modules can be
incorporated easily, without modifying the other
wiring or modules. The transmitted data is received
by every module connected to the control unit
network (CAN). As each data packet has an
identifier (label), in which the priority of the
message is determined as well as the content
identification, each module can detect whether or
not the data is relevant for its own information
processing. This enables several modules to be
addressed with a particular data packet and
supplied with data simultaneously. For this
purpose, it is ensured that important data (for
example from the ABS) is transmitted first. The
other modules are only able to submit their data to
the data bus after the high-priority messages have
been received.
The advantages of the CAN bus are:
Minimization of wiring requirements

High degree of error protection (fault / fail-proof)
Robustness
Good extendibility
Prioritization of messages
Inexpensive
Automatic repetition of faulty messages
Independent system monitoring and the ability
to disconnect faulty modules from the data bus
automatically
Due to the increased number of modules and the

resulting continued increase in data transfer, two
different CAN bus systems are used. Essentially,
they only differ in terms of their data transmission
rates and application areas.
To be able to distinguish between the individual
CAN bus systems, the CAN bus system with the
high transfer speed is called the high speed CAN
bus (HS-CAN). The data are transmitted at a baud
rate of 500 kB/s.
The CAN bus system with the medium transfer
speed is called the medium speed CAN bus
(MS-CAN) and is mainly used for communication
in the comfort electronics or the multimedia system.
The data are transmitted at a baud rate of 125 kB/s.
An interface (gateway) is used to exchange data
between the HS-CAN and the MS-CAN. This
provides the connection between the three CAN
databus systems and is installed in the GEM and
in the electronic instrument cluster. The number of
modules which are connected to the three databus
G1030779en

TO MODEL INDEX
418-00-8
418-00-8

systems depends on the equipment level of the
vehicle.
In order to guarantee a high degree of error
protection, two 120 Ohm terminating resistors are
installed in the CAN. These are integrated in the
first module connected to the CAN and in the last
module connected to the CAN respectively and
are used for suppression as well as the elimination
of voltage peaks. In order to ensure correct
functioning of the data bus system, the modules
must always be connected with an integral
terminating resistor. In order to enable
communication between the modules on the
HS-CAN and the modules on the MS-CAN, one
module is connected to both data bus systems.
The connection of both data bus systems is
designated as a gateway. In this gateway, the
received data is converted to the transmission rate
required for the relevant data bus and is
transmitted. This ensures an optimal distribution
of information between both data bus systems.
ABS
The GEM is integrated in the CJB (central junction
box) and cannot be replaced as a separate unit.
2008.50 Kuga 8/2011
G1030779en

TO MODEL INDEX
418-00-9
418-00-9
Communications Network
Terminal Probe Kit
418-S035
29011A
Digital multimeter

NOTE: Ensure correct locking of wiring harness
connectors.
Electrical
- Fuse(s)
- Wiring harness
- Connector
2008.50 Kuga 8/2011
G1055035en

TO MODEL INDEX
418-01-1
Module Configuration
418-01-1
SECTION 418-01 Module Configuration

CONTENTS
PAGE
GENERAL PROCEDURES
Module Configuration..........................................................................................................
Programmable Module Installation.....................................................................................
418-01-2
418-01-3

TO MODEL INDEX
418-01-2
418-01-2
GENERAL PROCEDURES
Activation
1. Install the most up-to-date software version in
the integrated diagnostic system (IDS).
2. In IDS, select the "Module reprogramming"
submenu in the "Module programming" menu
tool box and then follow the instructions.
3. Transfer a new software version (if available)
to the powertrain control module (PCM) using
IDS, if a module-reprogramming of the PCM
may be required in the case of engine running
concerns.
4. Following installation of a wheel/tire
combination, for which the tire-tread
circumference does not correspond to that of
standard tires, the tire size must be changed in
the PCM using IDS. Therefore select the
"Programmable parameters" submenu and enter
the corresponding tire size under the "tire size"
menu item.
2008.50 Kuga 8/2011
G1158256en

TO MODEL INDEX
418-01-3
418-01-3
GENERAL PROCEDURES
Programmable Module Installation

Activation
5. Install the most up-to-date software version in
IDS.
configured using IDS following replacement of

the lateral acceleration sensor, yaw rate sensor
or pressure sensor. Configuration is performed
in the "Programmable parameters" menu tool
box.
6. If, before replacing a module, it was not possible

to read out the vehicle-specific data using the
integrated diagnostic system (IDS) (the module
to be replaced does not respond) then, during
programming of the new module, the
vehicle-specific data must be entered manually
via a selection list in IDS or via a code which
can be obtained from the Technical Hotline.
7. In order to program, select the "Install
programmable module" submenu in the "Module
programming" menu tool box and then follow
the instructions.
8. The following modules must be programmed
after replacement:
Anti-lock braking system module (ABS)
Audio system module (ACM)
CD player (CDP)
Driver's door control unit (D-DCU)
Passenger's door control unit (P-DCU)
Rear left door control unit (RL-DCU)
Rear right door control unit (RR-DCU)
Electrical power steering (EPS)
Generic Display Module (GDM) (vehicles
with DVD navigation system with
touchscreen)
Generic electronic module (GEM)
Headlamp control module (HCM) (vehicles
with gas discharge headlamps)
Instrument cluster (IC)
Navigation system (NAV) (vehicles with
navigation system)
Parking aid module(PAM)
Powertrain control module (PCM)
Restraint control module (RCM)
Rear entertainment system module (RETM)
(vehicles with rear seat entertainment
system)
9. In order to configure the PCM, select the
"Programmable parameters" submenu in the
"Module programming" menu tool box and then
follow the instructions.
10. For vehicles with anti-lock braking system and
electronic stability program, these must also be
2008.50 Kuga 8/2011
G1158258en

TO MODEL INDEX
418-02-1
Wiring Harnesses
418-02-1
SECTION 418-02 Wiring Harnesses

CONTENTS
PAGE

Wiring Harness...................................................................................................................
418-02-2
418-02-2

Passenger Compartment Wiring Harness..........................................................................
Instrument Panel Wiring Harness.......................................................................................
Engine Compartment Wiring Harness................................................................................
418-02-4
418-02-24
418-02-37

TO MODEL INDEX
418-02-2
Wiring Harnesses
418-02-2
Wiring Harness
General Equipment
Ford approved diagnostic tool

2. Check the electrical connectors for security,

damage and incorrect connection. If the
electrical connectors are broken, damaged or
incorrectly connected, repair or replace the
components as required. TEST the system for
normal operation before proceeding to the next
step.
E61215
3. Disconnect the electrical connectors and check

for the following:
Moisture in the connector due to misaligned,
damaged or missing seals.
Contamination from leaking fluids in the region
of the connector.
2008.50 Kuga 8/2011
Damaged or oxidised connector pins.

Disengaged connector pins (this can be checked
by carefully pressing on the individual pins).
4. If any of the conditions listed are present, repair
or replace the components as required. TEST
the system for normal operation before
proceeding to the next step.
G1021921en

TO MODEL INDEX
418-02-3
Wiring Harnesses
418-02-3
E61216
1. Wiring harness.
2. Component.
5.
Check the wiring harness for the following:

Incorrect routing or installed too tightly.
Pinched or kinked sections.
Chafed insulation.
Security and orientation of retaining clips.
Damage in areas where the wiring harness is
subjected to noise, vibration and harshness
(NVH). For example, transmission or suspension
systems.
6. If any of the conditions listed are present, repair

or replace the components as required. TEST
the system for normal operation. If the concern
persists, REFER to the digital multimeter
function of the Ford approved diagnostic tool to
check the integrity of the wiring harness and
electrical connectors.
2008.50 Kuga 8/2011
G1021921en

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TO MODEL INDEX
Wiring Harnesses
418-02-10
28.
2008.50 Kuga 8/2011

E101750
E101749
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418-02-13
Wiring Harnesses
418-02-13

36. On both sides.
Refer to: B-Pillar Trim Panel (501-05 Interior
Installation).
37. On both sides.
Installation).
39. Refer to: Loadspace Trim Panel LH (501-05

and Installation).
Refer to: Loadspace Trim Panel RH (501-05
and Installation).
40. Remove the rear lamps.
41. On both sides.
Refer to: Front Seat (501-10 Seating, Removal
and Installation).
38. On both sides.

Refer to: D-Pillar Trim Panel (501-05 Interior
Installation).
42. Refer to: Rear Seat Backrest (501-10 Seating,

43. Refer to: Rear Seat Cushion (501-10 Seating,
44.
2008.50 Kuga 8/2011
G1065595en


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418-02-17

TO MODEL INDEX
Wiring Harnesses
418-02-17

50. Torque: 12 Nm
E114537
51.
2008.50 Kuga 8/2011
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418-02-21

TO MODEL INDEX
Wiring Harnesses
418-02-21

56.
E114543
57.
2008.50 Kuga 8/2011
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Wiring Harnesses
418-02-23

4. Insert the stripped ends of the wires into the
crimp connector.
E111773
5. Crimp the connection.
VFV3801004
6. Heat the shrink sleeving.

General Equipment: Hot Air Gun
VFV3801005
2008.50 Kuga 8/2011
G1065595en

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Wiring Harnesses
418-02-36

41.
E100844
Installation
2008.50 Kuga 8/2011
G1065597en

TO MODEL INDEX
418-02-37
Wiring Harnesses
418-02-37
Engine Compartment Wiring Harness

Removal
1.
2. Refer to: Headlamp Assembly (417-01 Exterior

Lighting, Removal and Installation).
3. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4. Refer to: Fender Splash Shield (501-02 Front
End Body Panels, Removal and Installation).
5. Refer to: Front Bumper Cover (501-19 Bumpers,
6. Torque: 10 Nm
E102365
7. Torque: 10 Nm
2008.50 Kuga 8/2011
G1065599en

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TO MODEL INDEX
Wiring Harnesses
418-02-41

24.
E102431
25.
2008.50 Kuga 8/2011
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Wiring Harnesses
418-02-43

28.
29. Torque: 10 Nm
Installation
1. To install, reverse the removal procedure .
2008.50 Kuga 8/2011
G1065599en

TO MODEL INDEX
419-01A-1
Anti-Theft - Active
419-01A-1
SECTION 419-01A Anti-Theft - Active

CONTENTS
PAGE

Anti-Theft - Active (Component Location)..........................................................................
Anti-Theft - Active (Overview).............................................................................................
Function check - Intrusion sensors.....................................................................................
Anti-Theft - Active (System Operation and Component Description).................................
System Diagram.................................................................................................................
Anti-theft warning system...............................................................................................
Interior scanning sensors................................................................................................
Anti-theft alarm horn with integral battery.......................................................................
419-01A-2
419-01A-4
419-01A-4
419-01A-5
419-01A-5
419-01A-6
419-01A-6
419-01A-7
419-01A-7
419-01A-7

Anti-Theft - Active...............................................................................................................
419-01A-8
Inspection and Verification.................................................................................................. 419-01A-8
Anti-Theft Alarm Horn.........................................................................................................
Anti-Theft Alarm Horn with Integral Battery........................................................................
419-01A-9
419-01A-11

TO MODEL INDEX
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Anti-Theft - Active
419-01A-3
419-01A-3

Item
12
Description
Anti-theft alarm system horn with
integrated battery (right-hand drive
vehicles)
2008.50 Kuga 8/2011
Item
Description
13
Switch for deactivation of interior scanning

sensors (right-hand drive vehicles)
G1066074en

TO MODEL INDEX
419-01A-4
Anti-Theft - Active
419-01A-4
Anti-Theft - Active Overview

The function of the anti-theft alarm system
components can be checked using the GEM's
service mode.
If an exact diagnosis is not possible using the
service mode, a system diagnosis must be carried
out with the Ford diagnostic unit. The last four
trigger signals from the anti-theft alarm signal can
also be read out during this process.
Function check - Intrusion sensors

Activate the anti-theft alarm system is check the
function of the intrusion sensors. After a waiting
time of approx. 30 seconds, perform movements
on both sides of the vehicle interior through the
open side windows. Each movement that is
detected is acknowledged through triggering of the
anti-theft alarm system.
2008.50 Kuga 8/2011
G1065778en

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Anti-Theft - Active
419-01A-6
419-01A-6

Item
Description
Item
Description
High speed CAN (controller area network)

bus (HS-CAN)
12
Driver's door set/reset switch
13
Driver's door door module
14
Medium speed CAN bus (MS-CAN)
15
RF receiver
Instrument cluster (gateway)
16
GEM
17
Hood contact switch
Anti-theft alarm system signal horn

(left-hand drive vehicles)
Folding rear window contact switch
18
Liftgate contact switch
Door ajar switch in all four doors
10
Switch for deactivation of interior scanning

sensors (right-hand drive vehicles)
Anti-theft alarm system horn with

integrated battery (right-hand drive
vehicles)
Refer to Component Description:
Anti-theft alarm horn with integral battery
(page ?)
11
Interior scanning sensors

?)
19
Hazard warning lights
System Operation
Anti-theft warning system
Three anti-theft alarm systems are available,
depending on the market and model version:
The system with perimeter monitoring detects
whenever the doors, the hood, the folding rear
window and the liftgate are opened.
The system with perimeter and interior
monitoring in addition detects unauthorised
access, for example, through a broken window.
A Thatcham category I anti-theft alarm system
(mainly for the British market) is fitted with a
horn that has its own battery power supply; it
also uses slightly different detection strategies.
If the hood, one of the doors, the folding rear

window or the liftgate is not completely closed, it
can be opened without the alarm being triggered
since the system was not activated.
The anti-theft alarm system can be switched off by
unlocking the vehicle either via the remote controls
or the door lock.
NOTE: To switch off the alarm on a Thatcham
category I anti-theft alarm system, the ignition must
be switched on within 12 seconds of the door being
unlocked with the key.
The anti-theft alarm system outputs an acoustic

and visual signal if unauthorised persons attempt
to gain access to the vehicle.
If the folding rear window or the liftgate is opened

via the remote control, the anti-theft alarm system
blocks the trigger for the alarm system or the
interior monitoring (if fitted) for 20 seconds after
closing.
As a visual warning, the system switches on the

hazard warning lights, whilst the acoustic warning
is done with the anti-theft alarm system horn or the
horn with its own battery power supply.
NOTE: If a window is not fully closed, there is a

risk that a false alarm will be triggered.
When the ignition is switched off, the anti-theft

alarm system is activated 20 seconds after any
latch is activated, i.e. the hood, all doors, the
folding rear window and the liftgate are alarmed,
provided that they are fully closed.
2008.50 Kuga 8/2011
G1065780en

TO MODEL INDEX
419-01A-7
Anti-Theft - Active
419-01A-7
This ensures that the alarm horn will still be

powered even if the vehicle battery has been
disconnected.
Interior scanning sensors
E100495
The interior monitoring is an additional security

system that triggers the alarm if unauthorised
access to the vehicle is detected in the area of the
windows.
The transceivers work ultrasonically. The
transmitter transmits at a specific frequency into
the monitoring area. The receiver receives the
corresponding echo signal. Here, the signals are
converted into digital values and compared with
the values from the signals received previously. If
there are significant differences between the two,
a trigger signal is sent to the GEM.
As the period during which no movement is
detected increases, so the sensitivity of the sensors
increases.
Anti-theft alarm horn with integral battery
E100563
A special horn is installed for vehicles that have to

comply with the Thatcham category I (CAT 1)
insurance standard. This horn has its own voltage
supply from an integrated battery.
2008.50 Kuga 8/2011
G1065780en

TO MODEL INDEX
Anti-Theft - Active
419-01A-8
419-01A-8
Anti-Theft - Active
Refer to Wiring Diagrams Section 419-01A, for
General Equipment

1. Verify the customer concern, perform a full
alarm function test
Mechanical
Misaligned door(s),
hood or tailgate
Door ajar switche(s)
Latch(es)
Cable(s)
Lock cylinder(s)
Set/reset switch(s)
Linkage(s)
Remote key
Passive key
Interior scanning
system
Interior scanning
system disable
button (if equipped)
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Relay(s)
Generic electronic
module (GEM)
Anti-theft alarm horn
Anti-theft alarm horn
with integral battery
(if equipped)

symptom and refer to the Ford approved
diagnostic tool to diagnose the system.
2008.50 Kuga 8/2011
G167420en
419-01A-9

TO MODEL INDEX
Anti-Theft - Active
419-01A-9
Anti-Theft Alarm Horn

Removal
1.
E101796
2.
2008.50 Kuga 8/2011
G1158260en

TO MODEL INDEX
Anti-Theft - Active
419-01A-10
419-01A-10
E101761
3.
E114491
Installation
2008.50 Kuga 8/2011
G1158260en

TO MODEL INDEX
419-01A-11
Anti-Theft - Active
419-01A-11
Anti-Theft Alarm Horn with Integral Battery

Removal
2.
E114592
3.
E114593
Installation
2008.50 Kuga 8/2011
G1065602en

TO MODEL INDEX
419-01B-1
Anti-Theft - Passive
419-01B-1
SECTION 419-01B Anti-Theft - Passive

CONTENTS
PAGE

Anti-Theft - Passive (Component Location)........................................................................
Anti-Theft - Passive (Overview)..........................................................................................
Programming the key.........................................................................................................
Transceiver of passive anti-theft system (emergency start function).................................
Anti-Theft - Passive (System Operation and Component Description)..............................
System Diagram.................................................................................................................
Passive Anti-theft System...............................................................................................
Keyless vehicle module (KVM).......................................................................................
Interior antennas.............................................................................................................
Passive key (radio remote control with integrated emergency key)...............................
RF receiver.....................................................................................................................
Transceiver of passive anti-theft system (emergency start function)..............................
Instrument cluster...........................................................................................................
419-01B-2
419-01B-3
419-01B-3
419-01B-3
419-01B-4
419-01B-4
419-01B-5
419-01B-5
419-01B-5
419-01B-5
419-01B-5
419-01B-5
419-01B-6
419-01B-6
419-01B-6

Anti-Theft - Passive............................................................................................................
419-01B-7
Inspection and Verification.................................................................................................. 419-01B-7

TO MODEL INDEX
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419-01B-3
419-01B-3
Anti-Theft - Passive Overview

Programming the key
After exchanging the keyless vehicle module
(KVM), all available keys must be reprogrammed
using the Ford diagnostic unit. Both the passive
key and the emergency key must be
reprogrammed.
In addition, the KVM must be initialized with the
following modules using the Ford diagnostic unit:
PCM
Steering Lock Unit
If a new key has to be added, only this key must
be programmed using the Ford diagnostic unit.
If a key is to be deleted, all keys must first be
deleted and the remaining keys reprogrammed.
Up to 8 keys can be programmed.
Transceiver of passive anti-theft system

(emergency start function)
Between the emergency key holder and the
passive anti-theft system transceiver, there is a
copper ring that ensures the resonant frequency
of the transceiver. If this copper ring is not in the
correct position, the function of the emergency key
cannot be guaranteed.
2008.50 Kuga 8/2011
G1065783en

TO MODEL INDEX
419-01B-4
419-01B-4
Anti-Theft - Passive System Operation and Component

Description
System Diagram
Item
Description
Item
Description

?)
Interior antennas
?)
Start/stop button
2008.50 Kuga 8/2011
G1065785en

TO MODEL INDEX
419-01B-5
419-01B-5

Item
Description
Item
Description
Passive key (radio remote control with

integrated emergency key)
?)
Transceiver of passive anti-theft system

(emergency start function)
?)
RF receiver
?)
Instrument cluster
?)
PCM
System Operation
Passive Anti-theft System
The passive anti-theft system PATS (passive
anti-theft system) is based on an electronic engine
immobiliser.
Interior antennas
The driver does not need to intervene in any way

to protect the vehicle, since PATS is automatically
activated when the ignition is switched off.
E100793
The four interior antennas transmit an LF signal

which is identified by the passive key.
Passive key (radio remote control with

integrated emergency key)
E100587
The PATS functionality is saved in the KVM. After

pressing the start/stop button, the KVM activates
the interior antennas, which then transmit a signal.
If there is a valid passive key in the vehicle interior,
it sends an encrypted signal to the radio frequency
receiver. The radio receiver forwards this signal to
the KVM via a fixed wire. The KVM then forwards
a corresponding identification query via the HS
CAN (controller area network) to the PCM.
E87065
If a valid code was received to this query, then the

engine can be started.
2008.50 Kuga 8/2011
G1065785en

TO MODEL INDEX
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TO MODEL INDEX
419-01B-7
419-01B-7
Refer to Wiring Diagrams Section 419-01B, for
General Equipment

Mechanical
Ignition lock cylinder
Passive anti-theft
system (PATS)
tranceiver
PATS ignition key
Use of a nonencoded PATS ignition key
More than one
PATS key in close
proximity of the
PATS transceiver
Powertrain control
module (PCM)
Keyless vehicle
module
Instrument cluster
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Relay(s)
PCM
PATS transceiver
Ignition switch
Instrument cluster
Keyless vehicle
module
PATS ignition key

symptom and refer to the Ford approved
diagnostic tool to diagnose the system.
2008.50 Kuga 8/2011
G1055072en

TO MODEL INDEX
419-10-1
Multifunction Electronic Modules
419-10-1
SECTION 419-10 Multifunction Electronic Modules

CONTENTS
PAGE

Module Controlled Functions (Overview)...........................................................................
Generic electronics module (GEM)....................................................................................
Emergency function............................................................................................................
Service mode......................................................................................................................
Module Controlled Functions (System Operation and Component Description)................
System Diagram.................................................................................................................
GEM................................................................................................................................
Battery charging (Smart Charge)....................................................................................
Ignition overload protection.............................................................................................
Headlamp switch-off delay..............................................................................................
Turn signals....................................................................................................................
Interior lighting................................................................................................................
Heated windscreen.........................................................................................................
Heated rear window and heated external mirrors...........................................................
Ambient air temperature.................................................................................................
Brake fluid level...............................................................................................................
Automatic headlamps.....................................................................................................
Windshield wash/wipe system........................................................................................
Anti-theft..........................................................................................................................
Electric booster Heater...................................................................................................
Climate control................................................................................................................
419-10-2
419-10-2
419-10-2
419-10-2
419-10-4
419-10-4
419-10-6
419-10-6
419-10-6
419-10-6
419-10-7
419-10-7
419-10-8
419-10-8
419-10-8
419-10-9
419-10-9
419-10-9
419-10-9
419-10-9
419-10-10
419-10-10
419-10-10
419-10-10

Generic Electronic Module (GEM)......................................................................................
419-10-11
Description of operation...................................................................................................... 419-10-11
Inspection and Checking.................................................................................................... 419-10-12
Generic Electronic Module (GEM)......................................................................................
Lighting Control Module (LCM)...........................................................................................
419-10-14
419-10-15

TO MODEL INDEX
419-10-2
419-10-2
Module Controlled Functions Overview

Generic electronics module (GEM)
CAUTIONS:
Never swap the GEM (generic electronic
module) between two vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
NOTE: The GEM is integrated in the CJB (central
junction box) and cannot be replaced as a separate
unit.
For repair work during a service, vehicle-specific
configuration is necessary if a new GEM is
installed.
Emergency function
The GEM is equipped with restricted emergency
running functions on vehicles with mid or high-end
equipment levels.
The microcontroller sends a control signal to a
monitoring function within the GEM at regular
intervals. If the battery voltage falls below a value
of approx. 7.5 volts, this check signal is not present
and the GEM switches to emergency function after
a predetermined time.
In this case, the low beam is permanently switched
on, regardless of the light switch position. The
windshield wiper can only be operated in stage 1;
the wiper switch must however be in the stage I or
II position. The wiper park position is not
recognized. Intermittent wiping is not available.
When the control signal recurs, the GEM switches
back to normal operation.
Service mode
Diagnosis of the GEM can be carried out using the
Ford diagnostic unit. Furthermore, an integrated
service mode enables testing of the input and
output signals without the need for further tools.
To enable activation of service mode:
2008.50 Kuga 8/2011

Shift to neutral

and HOLD IT THERE
SWITCH ON the ignition.
Inputs
SWITCH the windshield wiper switch to the "OFF"
particular order:

Rear window wiper
Doors open/closed
locking
A/C request signal
Parking brake
Brake fluid level
Cruise control system
Autolamps
Dipped beam
Main beam
Headlamp flasher
Side lights
G1030787en

TO MODEL INDEX
419-10-3
419-10-3
Reversing lamp
Liftgate release
Folding liftgate release

Test the windshield wiper "intermittent mode"
stage input signal (only vehicles with adjustable
intermittent mode):
Output signals
SWITCH the wiper switch to the "Intermittent"
Left-hand turn signal

Right-hand turn signal
Main beam
Dipped beam
Heated rear window
Heater blower motor
Headlamp washer system (vehicles with HID
headlamps)
Rear window wiper
Heated rear window relay

started.
of over 7km/h. However, service mode can be
follows:
2008.50 Kuga 8/2011

and HOLD IT THERE
Switch off the ignition.
Resetting service mode
Instrument cluster illumination, side marker
lamps (side lights) and licence plate lamp in
automatic headlamps mode
Rear wiper
Headlamp washer assembly
Alarm horn
Heated windshield
1. Switch off the ignition.
wash/wipe system
and HOLD IT THERE
4. SWITCH ON the ignition.
off automatically)
wash/wipe system
and HOLD IT THERE
functions.
G1030787en

TO MODEL INDEX
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TO MODEL INDEX
419-10-6
419-10-6

Item
Description
Item
Description
HS CAN
10
Mini-liftgate latch motor
DLC
11
Liftgate latch motor
MS CAN
12
Electric booster Heater
Instrument cluster (gateway)
13
Front wiper windscreen washer pump
Front windshield wiper motors
14
Rear wiper windscreen washer pump
GEM
15
Headlamp
Rear window wiper motors
16
Courtesy Lighting
Indicator/heated windshield
17
Alarm horn
Indicator/heated rear window
System Operation
GEM.
The following functions are controlled or performed
by the GEM at a battery voltage of between 9 and
16 volts:
Current distribution
Battery charging (Smart Charge)
Ignition overload protection
Turn signals
Interior lighting
Heated windscreen
Heated rear window and heated external mirrors
Ambient air temperature
Brake fluid level
Automatic headlamps
Windshield wash/wipe system
Speed control
reads the speed control switches and
transmits signals on the CAN data bus
central door locking
transmits signals on the CAN data bus
Anti-theft
Climate control
Parking brake
(monitors the switch and transmits the signal
on the CAN data bus
Communication via the medium-speed CAN
data bus
2008.50 Kuga 8/2011
Battery charging (Smart Charge)
In addition to the familiar functions, the Smart
Charge system also performs the following
functions:
Automatic deactivation of non-critical high power
is low in order to reduce the level of current
drawn.
Automatic activation of non-critical high power
is excessively high in order to protect
components which are sensitive to increased
voltages.
The battery charging current is optimized through
continuous calculation of the battery temperature
and monitoring of the alternator output voltage.
The alternator load is signaled to the PCM
(powertrain control module) in order to provide it
with an early indication when an electric component
is to be switched on or off, thereby also providing
information about imminent changes to the amount
of torque demanded by the alternator. By
evaluating this information the PCM is capable of
increasing the stability of the engine under idling.
The two remaining functions of the Smart Charge
system are controlled by the GEM.
G1030788en

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419-10-7
419-10-7

Electrical consumers are switched off when the
battery voltage is low if the GEM determines (as a
result of the message received from the PCM on
the CAN bus via the instrument cluster) that the
battery voltage has dropped below the threshold
value.
When the threshold for low battery voltage is
reached the GEM switches off the following
consumers in this order at intervals of 5 seconds:
Heated windscreen
Heated rear window
A/C system
If the battery voltage increases back above the

lower threshold then all of the consumers which
were previously switched off are reactivated by the
GEM.
by the GEM if the message "ignition switch in

position III" is received from the instrument cluster.
All of the electric consumers controlled by the
ignition overload protection relay are then switched
off.
The following consumers (among others) are
controlled by the ignition overload protection relay:
Fog lamps
Windscreen/rear window wash/wipe systems
Backup lamps
Heated washer nozzles
Heating blower motor
Seat heating
Once the electric consumers have been reactivated

their status is "switched off", i.e. the consumers
are switched off and await an input signal provided
from the relevant switch via the GEM; this means
that the driver needs to switch these components
back on again.
The headlamp switch-off delay utilizes the low

beam together with the peripheral lights (if
equipped) to illuminate the area surrounding the
vehicle. The function is activated by operating the
high beam lever when the ignition switch is in the
"0" position.
Electrical consumers are switched on when the

battery voltage is excessively high if the GEM
determines that the battery voltage has increased
above the threshold for overvoltage and the
charging system warning indicator has come on.
After the last door has been closed, the function

remains active for a further 30 seconds and then
switches off automatically.
When the threshold is reached the GEM switches

on the following consumers in this order at intervals
of 5 seconds:
Heated windscreen
Heated rear window
When these components are deactivated again
their status is "switched off". This means that the
consumers are waiting for an input signal provided
from the relevant switch via the GEM.
When a door or the tailgate is open, the switch-off

time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The switch-off time is adjusted to set values at the
factory and cannot be re-programmed using the
Ford diagnostic unit.
Ignition overload protection

The ignition overload protection intermittently
disconnects certain circuits in order to restrict the
current being drawn from the battery while the
starter motor is operating.
The position of the ignition switch is broadcast by
the instrument cluster on the medium speed CAN
bus.
The ignition overload protection relay which is
integrated in the battery junction box is activated
2008.50 Kuga 8/2011
G1030788en

TO MODEL INDEX
419-10-8
419-10-8

Turn signals
The interior lighting is switched on if one of the

following conditions is satisfied:
One of the vehicle's doors is opened.
1
The ignition key is in the "0" or "I" position and the

vehicle is unlocked.
The ignition key is turned from the "II" to the "I" or
"0" position.
The interior lighting is switched off when all of the
doors are closed and one of the following
conditions is satisfied:
E98941
Item
Description
External mirror housing
Turn signals
25 seconds have elapsed since the last door

was closed.
The ignition key is turned from the "0" or "I" to
the "II" position.
The ignition key is in the "0" or "I" position while
the vehicle is locked.
The GEM switches the direction indicators and the

direction indicator side repeaters on.
The dimmer function is not used if the interior

lighting is switched off via the battery protection
function.
The GEM sends a signal to the instrument cluster

via the CAN bus to switch on the relevant turn
indicator and the acoustic signal.
Heated windscreen
The signals from the hazard flasher switch and

from the multifunction switch are transmitted to the
GEM via a wiring connection.
The turn signals and the warning lamp flash at a
specified frequency and, in the case of failure of a
turn signal, the frequency is doubled.
The turn signal lamps also have a one-touch lane
change function. If the multifunction lever is
pressed just slightly then the relevant turn signal
lamp is actuated 3 times by the GEM.
Interior lighting
Depending on the vehicle specification, the interior
lighting includes:
Left and right-hand footwell lamps
Overhead lights at front and rear
Depending on the vehicle specification, the
switchable interior lighting includes:
Map lights
Mirror lights in sun visors
Glove compartment lamp
Luggage compartment lamp
The heated windshield is switched on by the GEM

under the following conditions:
The heated windshield switch is operated, the
ignition switch is in position "II" and the charge
warning lamp is switched off.
The "Defrost" function of the two-zone air
conditioning has been activated, the ignition
switch is in the position "II" and the charge
warning lamp is off.
The battery voltage has exceeded 16 V for more
than 20 seconds (power management strategy).
Manual requests for switching off the heated
windshield by pressing the switch are ignored
at this time.
The engine was started at an outside air
temperature below 4C and an engine
temperature below 65. Manual requests for
switching off the heated windshield by pressing
the switch are accepted.
NOTE: If the battery voltage returns to the normal
range, the disabling of the heated windshield is
switched off. It is then switched off.
The heated windshield is switched off by the GEM
The front and rear overhead lights are switched on

by the GEM.
2008.50 Kuga 8/2011
G1030788en

TO MODEL INDEX
419-10-9
419-10-9

4 minutes have elapsed since the button for the
heated windshield was pressed.
The ignition switch is turned to the "I" or "0"
position.
The "Defrost" function is deactivated or the
switch for the heated windscreen is pressed
again while the heated windscreen is still
switched on.
The charging system warning indicator is
switched on.
The battery voltage falls below the threshold
value for low battery voltage for more than 20
seconds (power management strategy). Manual
requests for switching on the heated windshield
by pressing the switch are ignored at this time.
More than 4 minutes have passed since starting
the engine.
Heated rear window and heated external

mirrors
The GEM transmits a request signal via the CAN
bus to the door modules to switch on the heated
exterior mirrors.
The heated rear window and the heated exterior
mirrors are switched on by the GEM under the
following conditions:
The switch for the heated rear window is
pressed and the ignition switch is in the "II"
position.
The "defrost" function of the air conditioning is
activated and the ignition switch is in the position
"II".
The battery voltage has exceeded 16 V for more
than 20 seconds (power management strategy).
Manual requests to switch off the heated rear
window by pressing the button are ignored at
this time.
The engine was started at an outside air
temperature below 4C and an engine
temperature below 65. Manual requests for
switching off the heated rear window by pressing
the switch are accepted.
NOTE: If the battery voltage returns to the normal
range then the disabling of the heated rear window
is cancelled - the heated rear window is then in a
switched-off state.
The GEM transmits a request signal via the CAN
bus to the door modules to switch off the heated
exterior mirrors.
2008.50 Kuga 8/2011
The heated rear window and the heated exterior

mirrors are switched off by the GEM under the
following conditions
14 minutes have elapsed since the button for
the heated rear window was pressed.
The ignition switch is turned to the position "0",
"I" or "III".
The switch for the heated rear window is
pressed or the "defrost" function of the air
conditioning is deactivated while the heated rear
window is switched on.
The battery voltage has dropped below 10.3 V
for more than 20 seconds (power management
strategy). Manual requests for switching on the
heated rear window by pressing the switch are
ignored at this time.
More than 14 minutes have passed since
starting the engine.
Ambient air temperature

The ambient air temperature sensor is connected
via a cable to the GEM. It measures the outside
air temperature to an accuracy of around 0.5 C.
The GEM broadcasts the ambient air temperature
on the medium speed CAN bus, where it can be
evaluated by various systems.
Brake fluid level

The brake fluid level switch is connected via a
cable to the GEM.
The GEM transmits a message on the medium
speed CAN bus. The instrument cluster then
transfers this message to the high speed CAN bus
where it is made available for various other
functions.
Automatic headlamps
Refer to: Exterior Lighting (417-01 Exterior Lighting,

Refer to: Exterior Lighting (417-01 Exterior Lighting,
G1030788en

TO MODEL INDEX
419-10-10
419-10-10

Windshield wash/wipe system
Refer to: Wipers and Washers (501-16 Wipers and
Washers, Description and Operation).
Anti-theft
Refer to: Anti-Theft - Active (419-01 Anti-Theft Active, Description and Operation).

Refer to: Auxiliary Climate Control (412-02 Auxiliary
Climate Control, Description and Operation).
Climate control
Refer to: Climate Control (412-01 Climate Control,
2008.50 Kuga 8/2011
G1030788en

TO MODEL INDEX
419-10-11
419-10-11

Terminal Probe Kit
418-S035
29011A
Digital multimeter
Switch off the ignition

Switch off all other electrical consumers
Apply the handbrake
Shift to neutral
Close the doors.
Activate service mode
Proceed as follows to activate service mode:

PRESS and HOLD the switch of the heated rear
window
SWITCH ON the ignition.
A signal sounds and the turn signal lamps
illuminate to indicate that service mode has been
NOTE: If the alarm is armed (in vehicles fitted with
an anti-theft alarm system), service mode cannot
be activated.
Input signals

particular order:
2008.50 Kuga 8/2011

Rear window wiper
Doors open/closed
Door key cylinder set/reset switch
locking
Hood up/down (in vehicles fitted with anti-theft
alarm system)
Mini liftgate open/closed
Manual A/C request signal
Manual AUX heater request signal
Heated windshield (if fitted)
Parking brake
Brake fluid level
Cruise control system
Autolamps
Dipped beam
Main beam
Headlamp flasher
Side lights
Reversing lamp
Tailgate release
Mini liftgate release
Interior scanning system

intermittent mode)

G1055084en

TO MODEL INDEX
419-10-12
419-10-12

Output signals

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
Left-hand turn signal

Right-hand turn signal
Main beam
Dipped beam
Heated rear windshield
Heater blower motor
Headlamp washer system (vehicles with HID
headlamps)
Autolamps (position lamps only if fitted)
Rear window wiper
Heated front window relay

started.
End service mode

of over 7km/h. However, service mode can be
follows:
PRESS and HOLD the switch of the heated rear
window
SWITCH OFF the ignition.
Reset service mode

Instrument cluster illumination, side marker
lamps (side lights) and licence plate lamp in
automatic headlamps mode
Rear wiper
Headlamp washer assembly
2008.50 Kuga 8/2011
Alarm horn
Heated windshield
wash/wipe system
and HOLD IT THERE
4. SWITCH ON the ignition.
off automatically)
wash/wipe system
and HOLD IT THERE
functions.

NOTE: The generic electronic module (GEM) is
integrated into the central junction box (CJB).
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or
electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection
Electrical
Fuses
Wiring harness
Connectors
G1055084en

TO MODEL INDEX
419-10-13
419-10-13

2008.50 Kuga 8/2011
G1055084en

TO MODEL INDEX
419-10-14
419-10-14

General Equipment
Removal
CAUTIONS:
4.
Modules must not be swapped between

vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
1
2
When installing a new GEM on vehicles

with a diesel engine, make sure that a fuel
pump fuse (F111) with 5A is used.
When installing a new GEM on vehicles
with a petrol engine, make sure that a fuel
pump fuse (F111) with 15A is used.
E102019
5.
NOTE: GEM is integrated into the central junction

box (CJB) and cannot be removed individually.
Upload the GEM configuration information using
the Programmable Modules Installation Routine.
E102020

Installation
3.

Download the GEM configuration information
to the newly installed GEM using the
programmable modules installation routine.
Program all keys using the Key Programming
Routine.
E51159
2008.50 Kuga 8/2011
G1065605en

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419-10-16
419-10-16

Calibrate the headlamp leveling system.
Refer to: Headlamp Adjustment (417-01 Exterior
Lighting, General Procedures).
2008.50 Kuga 8/2011
G1076572en
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204-00-3
204-00-3

Symptom
Steering wheel off center
Possible Sources
Action
Vehicle attitude incorrect (front Vehicles without load levelling

or rear is high or low).
shock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
Vehicles with load levelling
shock absorbers, GO to
Pinpoint Test C.
or damaged.
Suspension lower arm ball joint. CARRY OUT the Ball Joint
Inspection Component Test in
this procedure.
Incorrect wheel alignment.
ADJUST the wheel alignment.

REFER to: Front Toe Adjustment (204-00 Suspension
System - General Information, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Rough ride
Front strut and spring assem- CARRY OUT the Strut or

blies.
Shock Absorber Testing
component test in this
procedure.
CHECK and INSTALL new
suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disassembly and Assembly).
Front or rear stabilizer bar
connecting links or bushings.

necessary. REFER to:
Front Strut and Spring
Assembly (204-01 Front
Suspension, Disassembly
and Assembly),
Rear Stabilizer Bar (204-02
Rear Suspension, Removal
and Installation).
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-4
204-00-4

Symptom
Possible Sources
Front suspension lower arm
bushings.
Action
INSTALL a new lower arm.
REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
Rear suspension arm bushings. CHECK and INSTALL new

components as necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear
Suspension, Removal and
Installation).
Rear shock absorbers.
Excessive noise
CARRY OUT the Strut or

procedure.
necessary.
Front strut and spring assembly GO to Pinpoint Test B.

or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
Shock absorbers leaking.
Shock absorbers performance GO to Pinpoint Test B.

incorrect.
Stabilizer bar components.
Strut and spring assembly and GO to Pinpoint Test B.

springs.
Incorrect tire wear
Springs moving on springs

upper or lower seats.
Suspension bushings.
Lower arm ball joint.
Worn front wheel bearings
Wheels and tires.
Front or rear suspension

damage.

necessary.

REFER to: Front Toe Adjustment (204-00 Suspension
System - General Information, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-5
204-00-5

Symptom
Vibration
Possible Sources
Action
Damaged or worn front wheel CHECK the front wheel bearbearings.

ings.
Wheels and tires.
CHECK the tires. BALANCE or

INSTALL new tires as necessary.

or damaged.
Front strut and spring assem- CARRY OUT the Strut or
blies.
procedure.
necessary.
and Installation).
Damaged front suspension
lower arm(s).

necessary.
REFER to: Lower Arm (204-01
and Installation).
Vehicle lean
Load-levelling shock absorbers. GO to Pinpoint Test C.
Pinpoint Tests
PINPOINT TEST A : DRIFT LEFT OR RIGHT
TEST CONDITIONS
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-6
204-00-6

TEST CONDITIONS
always be maintained on the steering wheel. Failure to follow these instructions may result
in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (10002 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
Road test the vehicle.
Does the vehicle drift?
Yes
GO to A2.
No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
Swap the rear left-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
Yes
GO to A3.
No
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-7
204-00-7

TEST CONDITIONS
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES

assembly with the rear left-hand wheel and
tire assembly.
Yes
GO to A4.
No
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
Swap the front right-hand wheel and tire
tire assembly.
Yes
GO to A5.
No
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
tire assembly.
Yes
GO to A6.
No
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-8
204-00-8

TEST CONDITIONS
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY

Swap the front right-hand wheel and tire
assembly with the rear left-hand wheel and
tire assembly.
Yes
GO to A7.
No
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels. TEST
the system for normal operation.
Yes
Verify possible sources, refer to the Symptom
Chart.
No
PINPOINT TEST B : EXCESSIVE NOISE
TEST CONDITIONS
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
1 Inspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
Are the mounting bolts or nuts loose or broken?
Yes
TIGHTEN or INSTALL new suspension
mounting bolts.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
No
GO to B2.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-9
204-00-9

TEST CONDITIONS
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE: Make sure that the oil is not from another
source.
1 Inspect the strut and spring assemblies and
shock absorbers for signs of oil weepage or
leaks. Refer to weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
Are the struts or shock absorbers leaking?
Yes
INSTALL new struts or shock absorbers as
necessary.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
No
GO to B3.
B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1 Inspect the springs and stabilizer bar(s) for
damage.
Are the springs or stabilizer bar(s) damaged?
Yes
INSTALL new springs or stabilzer bar(s).
REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspension, Removal and Installation).
No
GO to B4.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-10
204-00-10

TEST CONDITIONS
B4: INSPECT THE SUSPENSION BUSHINGS

1 Inspect the suspension bushings for excessive
wear or damage.
Are the bushings worn or damaged?
Yes
INSTALL new components as necessary.
REFER to:
Lower Arm (204-01 Front Suspension, Removal
and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspension, Removal and Installation).
No
GO to B5.
B5: INSPECT THE SUSPENSIONS LOWER ARM BALL JOINTS
1 Carry out the Ball Joint Inspection component
test in this procedure.
Is the lower arm ball joint or gaiter damaged?
Yes
INSTALL new lower arm.
REFER to: Lower Arm (204-01 Front
TEST the system for normal operation.
No
GO to B6.
B6: INSPECT THE WHEEL BEARINGS
1 Check the wheel bearings.
Are the wheel bearings damaged?
Yes
INSTALL a new wheel hub(s).
REFER to: Wheel Hub (204-01 Front
No
GO to B7.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-11
204-00-11

TEST CONDITIONS
B7: INSPECT THE WHEEL AND TIRES

1 Inspect the tires for uneven wear.
Is there uneven wear?
Yes
REFER to the symptom chart.
No
GO to B8.
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
1 Loosen the strut and spring assemblies and
shock absorbers top and bottom mounting bolts
and nuts. Tighten the mounting bolts and nuts.
REFER to:
Specifications (204-01 Front Suspension,
Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
Is the concern still evident?
Yes
GO to B9.
No
Vehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER COMPONENTS
1 Check that the spring is correctly located on the
spring seat and has not moved.
2 Disassemble the strut and spring and assembly
and inspect the individual components.
Installation).
3 Inspect the shock absorber top mount for wear
or damage.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-12
204-00-12

TEST CONDITIONS
4 Carry out the Strut or Shock Absorber Testing
component test in this procedure.
Are any of the strut and spring assemblies or
shock absorber components damaged?
Yes
REFER to:
Spring (204-02 Rear Suspension, Removal and
Installation).
No
REINSTALL the strut and spring assemblies
or shock absorbers. GO to C1.
PINPOINT TEST C : VEHICLE LEAN
TEST CONDITIONS
C1: VEHICLE LEAN

1 Detach the load levelling shock absorbers from
the wheel knuckles.
Does the vehicle lean?
Yes
Install new rear springs.
REFER to: Spring (204-02 Rear Suspension,
No
CARRY OUT the Load-Levelling Shock
Absorber Component Test in this section.
Component Tests
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting)
2. If there is any free movement install a new lower

arm.
REFER to: Lower Arm (204-01 Front

Ball Joint Inspection

1. Firmly grasp the outer end of the suspension
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an
audible "click''. There should be no free
movement.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-13
204-00-13

3. If a new lower arm is installed it will be
necessary to check and adjust the front wheel
alignment.
REFER to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures)
/ Rear Toe Adjustment (204-00 Suspension
Procedures).
4. Compress and pull the piston rod in the vertical

position. Feel if the resistance force at the point
of direction change-over is perceptible without
a lag. If a lag is perceptible it is an indication of
damper valve damage and new struts or shock
absorbers must be installed. REFER to:
Spring (204-02 Rear Suspension, Removal and
Installation).
Strut or Shock Absorber Inspection

Load-Levelling Shock Absorber
NOTE: Inspect the struts or shock absorber for
signs of oil weepage or leaks. Make sure that the
oil is not from another source.
Weepage:
deposits a thin film of oil on the strut and spring
assembly or shock absorber.
is normally noticed due to a collection of dust
on the strut and spring assembly or shock
absorber.
occurs during the normal running-in period of
4800 - 8050 km. After this period no new signs
of oil should be visible.
does not require new struts or shock absorbers
to be installed.
Leakage:
covers the entire strut and spring assembly or
shock absorber with oil.
will drip oil onto the surrounding suspension
components.
requires new struts or shock absorbers to be
installed.
Strut or Shock Absorber Testing

NOTE: Struts or shock absorbers must be tested
in the vertical position.
1. Remove both strut and spring assemblies or
shock absorbers. The piston rods should extend.
Disassemble the strut and spring assemblies.
Installation).
2. Compress the piston rods. Both piston rods
should offer the same resistance when
compressing.
3. Compress and release the piston rods. The
piston rods should extent equally.
2008.50 Kuga 8/2011
1. With the vehicle unladen, measure and note the

dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
The measurements on both sides should be
approximately equal.
2. With a load of 4 average size adults and a 100
kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
3. NOTE: Due to the internal ratchet mechanism
of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
With a load of 4 average size adults and a 100
kg weight, drive the vehicle for 3 km on a road
of normal condition.
4. With a load of 4 average size adults and a 100
kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
5. If the dimensions on both sides are no longer
approximately equal, install new load levelling
shock absorbers.
6. NOTE: Due to the internal ratchet mechanism
of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
If the dimensions are approximately equal,
unload the vehicle and drive the vehicle for 3
km on a road of normal condition.
7. With the vehicle unladen, measure and note the
dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
Check the final dimensions with the original
dimensions taken in the unladen condition.
G1080717en

TO MODEL INDEX
204-00-14
204-00-14

8. If the final dimensions do not approximately
equal the original dimensions, install new load
levelling shock absorbers.
9. If the final dimensions approximately equal the
original dimensions, verify the customer
concern.
2008.50 Kuga 8/2011
G1080717en

TO MODEL INDEX
204-00-15
204-00-15
GENERAL PROCEDURES
Front Toe Adjustment(14 117 3)

General Equipment
Wheel Alignment System
NOTE: Make sure that the vehicle is standing on
a level surface.
1.
CAUTION: Make sure that the steering

wheel lock is engaged.
NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
2. Check the toe setting on both sides.

General Equipment: Wheel Alignment System
3. 1. Loosen on both sides.
Torque: 69 Nm
2. NOTE: Make sure that the boot is correctly
located.
Rotate the tie-rods an equal amount in either
a clockwise or a counterclockwise direction
to adjust the toe setting on both sides.
E67410
2008.50 Kuga 8/2011
G1000721en

TO MODEL INDEX
204-00-16
204-00-16
GENERAL PROCEDURES
Rear Toe Adjustment(15 211 3)

General Equipment
Wheel Alignment System
a level surface.
7. NOTE: Only tighten the nuts and bolts when the

suspension is in the normal drive position.
Torque: 90 Nm
1. Check the toe setting.

Refer to: Specifications (204-02 Rear
Suspension, Specifications).
General Equipment: Wheel Alignment System
3. Loosen the rear lower arm adjustment cam nut
on both sides.
Torque: 18 Nm
E69309
E69309
4. Lower the vehicle.

5. Bounce the vehicle to make sure that the
suspension is in its normal resting position.
6. Adjust the toe setting.
E69678
2008.50 Kuga 8/2011
G1000722en

TO MODEL INDEX
204-01-1
Front Suspension
204-01-1
SECTION 204-01 Front Suspension

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
204-01-2

Front Suspension (Component Location)...........................................................................
Front Suspension (Overview).............................................................................................
Overview.............................................................................................................................
Spring and damper assembly.............................................................................................
Subframe............................................................................................................................
Stabilizer bar.......................................................................................................................
204-01-3
204-01-4
204-01-4
204-01-5
204-01-6
204-01-7

Wheel Hub...................................................................................................... (14 371 0)
Front Wheel Bearing....................................................................................... (14 411 0;
14 411 4;
14 412 0;
14 414 4;
14 416 4)
Lower Arm...................................................................................................... (14 706 0;
14 707 0;
14 709 0)
Front Stabilizer Bar......................................................................................... (14 752 0)
Front Stabilizer Bar Bushing........................................................................... (14 754 0;
14 754 4)
Wheel Knuckle................................................................................................ (14 343 0)
Front Strut and Spring Assembly.................................................................... (14 781 0;
14 782 0)
204-01-8
204-01-9
204-01-13
204-01-15
204-01-20
204-01-21
204-01-26

Front Strut and Spring Assembly.................................................................... (14 783 4)
204-01-29

TO MODEL INDEX
Front Suspension
204-01-2
204-01-2
SPECIFICATIONS
Front Wheel Alignment 2WD (at curb weight)
Descri Measurem Toler- Setting Maximum
ption
ents
ance
or
VariRange Nominal ance
Left or
Right
Caster
angle
Camber
angle
Total
toe
Degrees
and
minutes
326'
to
526'
426'
100'
Decimal
degrees
3.44
to
5.44
4.44
1.00
Degrees
and
minutes
-203'
to
+027'
-048'
115'
Decimal
degrees
-2.05
to 0.45
-0.80
1.25
mm
1.5
Toe-in
2.6
1.5
Toe-in
1.1
Degrees
and
minutes
012'
012'
Toe-in Toe-in
021' 009'
Decimal
degrees
0.20
0.20
Toe-in Toe-in
0.35 0.15
2008.50 Kuga 8/2011
Front Wheel Alignment 4WD (at curb weight)

ption
ents
ance
or
Left or
Right
Caster
angle
Camber
angle
Total
toe
Degrees
and
minutes
322'
to
522'
422'
100'
Decimal
degrees
3.37
to
5.37
4.37
1.00
Degrees
and
minutes
-202'
to
+028'
-047'
115'
Decimal
degrees
-2.03
to 0.47
-0.78
1.25
mm
1.5
Toe-in
2.6
1.5
Toe-in
1.1
Degrees
and
minutes
012'
012'
Toe-in Toe-in
021' 009'
Decimal
degrees
0.20
0.20
Toe-in Toe-in
0.35 0.15
G1000726en

TO MODEL INDEX
204-01-3
Front Suspension
204-01-3
Front Suspension Component Location
E98521
2008.50 Kuga 8/2011
G1055776en

TO MODEL INDEX
Front Suspension
204-01-4
204-01-4
Front Suspension Overview

Overview
5
6
9
4
10
2
8
E96874
Item
Description
Item
Description
Subframe
Shock absorber
Lower arm
Stabilizer bar link
Stabilizer bar
Spring
Wheel knuckle
Heat shield
2008.50 Kuga 8/2011
G1000166en

TO MODEL INDEX
Front Suspension
204-01-5
204-01-5

Item
9
Description
Item
Stabilizer bar bushes and bracket
10
Description
Wheel hub
Spring and damper assembly
2
5
E96884
Item
Description
Item
Description
Shock absorber
Gaitor
Spring
Bearing
Spring aid
Top mount assembly
Retaining nut
The following components may be renewed:

Shock absorber
Spring
Spring aid
Gaitor
Bearing
Top mount assembly
Retaining nut
2008.50 Kuga 8/2011
During removal and installation or renewal of

components of the spring and damper assembly,
pay attention to the following:
Prior to installation of the spring and damper
assembly, the bearing and support bearing must
be aligned according to the installation
instructions.
Take extra care when handling the compressed
spring.
After completing the work, the suspension
geometry of the vehicle must be checked and
corrected as necessary.
G1000166en

TO MODEL INDEX
Front Suspension
204-01-6
204-01-6

Subframe
3
2
1
2
E96885
Item
Description
Subframe
Rear bushes, subframe
Front bushes, subframe

Subframe
Subframe bushes
2008.50 Kuga 8/2011

components of the subframe, pay attention to the
following:
Before installing the subframe bushes, they
must be aligned according to the installation
instructions.
When the subframe is installed or removed, it
must be aligned with the vehicle body using the
appropriate special tools.
G1000166en

TO MODEL INDEX
Front Suspension
204-01-7
204-01-7

Stabilizer bar
E98611
Item
Description
Stabilizer bar
Bushes, stabilizer bar
Bracket, stabilizer bar bushes

Stabilizer bar
components of the stabilizer bar, pay attention to
the following:
Before installing the stabilizer bar bushes, they
instructions.
2008.50 Kuga 8/2011
G1000166en

TO MODEL INDEX
204-01-8
Front Suspension
204-01-8
Wheel Hub(14 371 0)

Removal
1. Refer to: Front Wheel Bearing (204-01 Front
Installation
2008.50 Kuga 8/2011
G1000205en

TO MODEL INDEX
Front Suspension
204-01-9
204-01-9
Front Wheel Bearing(14 411 0; 14 411 4; 14 412 0; 14 414 4;

14 416 4)
204-158
Collet for 205-295

205-295
Remover, Bearing (Main
Tool)
15050A
14038
204-348
Remover/Installer, Wheel
Hub/Wheel Bearing
Hydraulic Press
Removal
1. Refer to: Wheel Knuckle (204-01 Front
E42977
204-740
Remover/Installer, Wheel
Hub/Bearing

before removal.
E100141
205-071-01
Adapter for 205-071 (Thrust
Pad)
E99320
15026A01
205-080
Installer, Differential Bearing
205080
205-255
Installer, Front Wheel Hub
Seal
14045
2008.50 Kuga 8/2011
G1000206en

TO MODEL INDEX
Front Suspension
204-01-10
204-01-10

3. Special Tool(s): 205-080, 204-348
General Equipment: Hydraulic Press
4. Special Tool(s): 205-255, 204-740

205-080
204-348
E99321
205-255
204-740/2
E99322
5. Special Tool(s): 205-071-01, 205-295, 204-158
2008.50 Kuga 8/2011
G1000206en

TO MODEL INDEX
Front Suspension
204-01-11
204-01-11
205-071-01
204-158
205-295
E99400
6.
E103391
Installation
1. NOTE: Make sure that the sensor ring is
correctly located.
2008.50 Kuga 8/2011
G1000206en

TO MODEL INDEX
Front Suspension
204-01-12
204-01-12

Install the wheel bearing with the black colored
wheel speed sensor ring facing towards the
transmission side.
2. Special Tool(s): 204-740


204-740/1
204-740/1
E99403
E99402
3. NOTE: Make sure that this component is

installed to the noted removal position.
E99320
4. Refer to: Wheel Knuckle (204-01 Front

2008.50 Kuga 8/2011
G1000206en

TO MODEL INDEX
Front Suspension
204-01-13
204-01-13
Lower Arm(14 706 0; 14 707 0; 14 709 0)

3. Torque: 83 Nm
Special Tool(s)
204-605
Separator, Lower Arm Ball
Joint
E63772
204-609
Protection Cap, Ball Joint
Gaiter
E97635
4. If equipped.
Torque: 8 Nm
E75372
Removal
2.
E75215
x7
E98543
204-605
E97732
2008.50 Kuga 8/2011
G1000207en

TO MODEL INDEX
Front Suspension
204-01-14
204-01-14

204-609
E81908
7.
CAUTION: Make sure that new bolts are

installed.
1. Torque:
Stage 1: 100 Nm
Stage 2: Loosen 90
Stage 3: 125 Nm
2. Torque: 175 Nm
1
1
E97634
Installation
2. Check the toe setting and adjust as necessary.
Refer to: Front Toe Adjustment (204-00
2008.50 Kuga 8/2011
G1000207en

TO MODEL INDEX
Front Suspension
204-01-15
204-01-15
Front Stabilizer Bar(14 752 0)

On both sides.
Torque: 47.5 Nm

205-316A
15097A
Hydraulic Press
Transmission Jack
E91648
Removal
5.
CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent.

2.
x7
E98334
6.
E98543
3. If equipped.
Torque: 8 Nm
E98346
E75215
4.
CAUTION: Make sure that the ball joint

ball does not rotate.
2008.50 Kuga 8/2011
G1000208en
204-01-16

TO MODEL INDEX
Front Suspension
204-01-16

7. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
9. General Equipment: Transmission Jack
E99060
E89385
8. Torque:
Stage 1: 40 Nm
Stage 2: 60
10. Remove the following items:

1. Torque: 70 Nm
2. Torque:
Stage 1: 140 Nm
Stage 2: 180
3. Torque: 125 Nm
E98557
2008.50 Kuga 8/2011
G1000208en

TO MODEL INDEX
Front Suspension
204-01-17
204-01-17
4
3
120 mm
E98979
11. Torque: 47.5 Nm
12. NOTE: Note the position of each component

before removal.
E99063
E68087
Installation
1. NOTE: Make sure that the component is clean,
free of foreign material and lubricant.
2008.50 Kuga 8/2011
G1000208en

TO MODEL INDEX
204-01-18
Front Suspension
204-01-18

NOTE: Make sure that these components are
2. NOTE: Make sure that the clamp is installed to

the same orientation as when removed.
On both sides.
E67369
E89914
3. On both sides.

5. Install the Special Tool(s): 205-316A
E69763
2008.50 Kuga 8/2011
G1000208en

TO MODEL INDEX
204-01-19
Front Suspension
204-01-19
205-880
E99249
6. Refer to: Front Toe Adjustment (204-00

2008.50 Kuga 8/2011
G1000208en

TO MODEL INDEX
204-01-20
Front Suspension
204-01-20
Front Stabilizer Bar Bushing(14 754 0; 14 754 4)

Removal
1. Refer to: Front Stabilizer Bar (204-01 Front
Installation
1.
2008.50 Kuga 8/2011
G1000758en

TO MODEL INDEX
Front Suspension
204-01-21
204-01-21
Wheel Knuckle(14 343 0)

Special Tool(s)
1.
204-052
Lever, Wheel Knuckle
14026A
204-602
Installer, Halfshaft
E99184

E62067
204-605
Joint
3.
E63772
204-609
Gaiter
E99195
E75372
4.
211-020
Separator, Ball Joint
x7
13006
Removal
E98543

2008.50 Kuga 8/2011
5.
WARNING: Make sure that no load is

placed on the brake hose.
Torque: 120 Nm
G1000209en

TO MODEL INDEX
204-01-22
Front Suspension
204-01-22
E100801
6. Refer to: Front Wheel Speed Sensor (206-09

Anti-Lock Control - Stability Assist, Removal
and Installation).
8. If equipped.
Torque: 9 Nm
7.
E99270
E67589
2008.50 Kuga 8/2011
G1000209en

TO MODEL INDEX
Front Suspension
204-01-23
204-01-23

9. Torque: 83 Nm
204-609
E97635
E81908
10. If equipped.
Torque: 8 Nm
13.

Torque: 48 Nm
E75215
E99197

14. Install the Special Tool(s): 211-020
204-605
211-020
E97732
E99198
2008.50 Kuga 8/2011
G1000209en

TO MODEL INDEX
Front Suspension
204-01-24
204-01-24

15. Remove the Special Tool(s): 211-020
17. Torque: 90 Nm
16.
E99255
E99196
2
204-052
1
3
E99214
19. Refer to: Wheel Hub (204-01 Front Suspension,

Installation
2008.50 Kuga 8/2011
G1000209en

TO MODEL INDEX
204-01-25
Front Suspension
204-01-25

Torque: 45 Nm
204-161
E99268

4. Torque: 100 Nm
E99269

6. Torque: 270 Nm
E99195
2008.50 Kuga 8/2011
G1000209en

TO MODEL INDEX
Front Suspension
204-01-26
204-01-26
Front Strut and Spring Assembly(14 781 0; 14 782 0)

Special Tool(s)
204-159
Removal
14039
2.
204-605
Joint
E63772
E101070
2008.50 Kuga 8/2011
G1000210en

TO MODEL INDEX
204-01-27
Front Suspension
204-01-27

4. If equipped.
Torque: 8 Nm
5.

Torque: 47 Nm
E99103
E75215
6. Torque: 90 Nm
E99108
7. Special Tool(s): 204-159, 204-605
2008.50 Kuga 8/2011
G1000210en

TO MODEL INDEX
Front Suspension
204-01-28
204-01-28
204-159
204-605
E99109
8.
WARNING: This step requires the aid of

another technician.
Torque: 35 Nm
x3
E99147
Installation
2008.50 Kuga 8/2011
G1000210en

TO MODEL INDEX
Front Suspension
204-01-29
204-01-29
Front Strut and Spring Assembly(14 783 4)

Special Tool(s)
204-167
Compressor, Coil Spring
Disassembly
WARNING: Take extra care when handling
the compressed spring.
1. Install the Special Tool(s): 204-167, 204-167-01
14042
204-167-01
Adapter for 204-167
204-167-01
1
1404201
204-167
E97819

before removal.
E132038
2008.50 Kuga 8/2011
G1000221en

TO MODEL INDEX
204-01-30
Front Suspension
204-01-30

Assembly
WARNING: Take extra care when handling
the compressed spring.
3. To assemble, reverse the disassembly
procedure.
5. NOTE: Make sure that these components are

NOTE: Make sure that the spring is correctly
located in the lower spring seat.
NOTE: Make sure that the installation marks
are aligned.
4. NOTE: Only tighten the nut finger tight at this

stage.
E98495
E131947
2008.50 Kuga 8/2011
G1000221en

TO MODEL INDEX
204-01-31
Front Suspension
204-01-31

6.
CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Torque: 55 Nm
E98495
7. Remove the Special Tool(s): 204-167,

204-167-01
2008.50 Kuga 8/2011
G1000221en

TO MODEL INDEX
204-02-1
Rear Suspension
204-02-1
SECTION 204-02 Rear Suspension

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
204-02-2

Rear Suspension (Overview)..............................................................................................
Overview.............................................................................................................................
Upper control arm...............................................................................................................
Rear lower arm and spring lower pad.................................................................................
Front lower arm..................................................................................................................
Stabilizer bar.......................................................................................................................
204-02-3
204-02-3
204-02-4
204-02-4
204-02-4
204-02-5

Wheel Bearing and Wheel Hub..........................................................................................
Upper Arm...................................................................................................... (15 701 0)
Front Lower Arm............................................................................................. (15 690 0)
Rear Lower Arm............................................................................................. (15 705 0)
Rear Stabilizer Bar......................................................................................... (15 752 0)
Rear Stabilizer Bar Link......................................................................................................
Rear Stabilizer Bar Bushing...............................................................................................
Wheel Knuckle LHD FWD/RHD FWD............................................................................
Wheel Knuckle LHD 4WD/RHD 4WD............................................................................
Spring............................................................................................................. (15 621 0)
204-02-6
204-02-9
204-02-11
204-02-13
204-02-15
204-02-17
204-02-18
204-02-19
204-02-22
204-02-25

TO MODEL INDEX
Rear Suspension
204-02-2
204-02-2
SPECIFICATIONS
Rear Wheel Alignment 2WD
ption
ents
ance
or
Left or
Right
Camber
angle
Single
wheel
toe
Total
toe
Degrees
and
minutes
-247'
to 017'
-132'
115'
Decimal
degrees
-2.79
to 0.29
-1.54
1.25
mm
1.4
1.3
1.4
Toe-in
0.6
Degrees
and
minutes
011'
010'
011'
Toe-in
005'
Decimal
degrees
0.19
0.18
mm
Rear Wheel Alignment 4WD

ption
ents
ance
or
Left or
Right
Camber
angle
Degrees
and
minutes
-2.47'
to 017'
-132'
115'
Decimal
degrees
-2.79
to 0.29
-1.54
1.25
mm
1.4
1.3
1.4
Toe-in
0.6
Degrees
and
minutes
011'
010'
011'
Toe-in
005'
0.19
Toe-in
0.08
Decimal
degrees
0.19
0.18
0.19
Toe-in
0.08
2.8
2.6
2.8
Toe-in
1.1
mm
2.8
2.6
2.8
Toe-in
1.1
Degrees
and
minutes
023'
021'
023'
Toe-in
009'
Degrees
and
minutes
023'
021'
023'
Toe-in
009'
Decimal
degrees
0.38
0.35
0.38
Toe-in
0.15
Decimal
degrees
0.38
0.35
0.38
Toe-in
0.15
Torque Specifications
Item
Single
wheel
toe
Total
toe
Nm
lb-ft
lb-in
Rear Shock Absorber - Upper Fixing
18
14
160
Rear Shock Absorber - Lower Fixing
115
85
1018
2008.50 Kuga 8/2011
G1000727en

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Rear Suspension
204-02-3
204-02-3
Rear Suspension Overview

Overview
9
10
6
1
3
4
E98609
Item
Description
Item
Description
Subframe
Wheel knuckle
Rear lower arm and spring lower pad
Tie-bar
Spring
Shock absorber
Stabilizer bar link
Upper control arm
Front lower arm
10
Stabilizer bar, bushings and clamps
2008.50 Kuga 8/2011
G1000191en

TO MODEL INDEX
204-02-4
Rear Suspension
204-02-4

Upper control arm

Lower arms
During removal and installation or renewal of the
lower arm, pay attention to the following:
Front lower arm
E98616

Lower arms
E98614
Rear lower arm and spring lower pad

Lower arms
E98615
2008.50 Kuga 8/2011
G1000191en

TO MODEL INDEX
Rear Suspension
204-02-5
204-02-5

Stabilizer bar
E98611
Item
Description
Stabilizer bar

Stabilizer bar
components of the stabilizer bar, pay attention to
the following:
Before installing the stabilizer bar bushes, they
instructions.
2008.50 Kuga 8/2011
G1000191en

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204-02-6
Rear Suspension
204-02-6
Wheel Bearing and Wheel Hub

Removal
5. If equipped.

2. Refer to: Rear Wheel Speed Sensor (206-09
and Installation).
3.

E134127
All vehicles
6.
E100132
4x4
4.
E99212
E101209
2008.50 Kuga 8/2011
G1001323en

TO MODEL INDEX
Rear Suspension
204-02-7
204-02-7

7.
2.
x4
E99212
4x4
4
3. NOTE: Only tighten the bolt finger tight at this

stage.
E99213
Installation
E101209
1. Torque: 110 Nm
All vehicles
4.
1
3

Torque: 110 Nm
4
2
E133879
2008.50 Kuga 8/2011
E134113
G1001323en

TO MODEL INDEX
204-02-8
Rear Suspension
204-02-8

5. Refer to: Rear Wheel Speed Sensor (206-09
and Installation).
4x4
7. Torque: 50 Nm
E134128
8. If equipped.
E134126
2008.50 Kuga 8/2011
G1001323en

TO MODEL INDEX
204-02-9
Rear Suspension
204-02-9
Upper Arm(15 701 0)

General Equipment
Transmission Jack

Removal
2. Refer to: Spring (204-02 Rear Suspension,


3. Fabricate a spacer.
40
226
E69209
E93313
2008.50 Kuga 8/2011
G1000224en

TO MODEL INDEX
204-02-10
Rear Suspension
204-02-10

5. Torque: 115 Nm
E67803
6. Torque: 115 Nm
E67804
Installation
2. Refer to: Rear Toe Adjustment (204-00
2008.50 Kuga 8/2011
G1000224en

TO MODEL INDEX
204-02-11
Rear Suspension
204-02-11
Front Lower Arm(15 690 0)

General Equipment
Transmission Jack

Removal
40
226
E69209
E93313
2008.50 Kuga 8/2011
G1000225en

TO MODEL INDEX
204-02-12
Rear Suspension
204-02-12

4. Torque: 115 Nm
E67810
Installation
2008.50 Kuga 8/2011
G1000225en

TO MODEL INDEX
Rear Suspension
204-02-13
204-02-13
Rear Lower Arm(15 705 0)

3.
General Equipment
Transmission Jack
Removal
40
E69403
Installation
226
1. NOTE: Only tighten the nuts finger tight at this

stage.
E69209
E69403
2008.50 Kuga 8/2011
G1000226en

TO MODEL INDEX
204-02-14
Rear Suspension
204-02-14
E93313
3. 1. Torque: 18 Nm
2. Torque: 115 Nm
E67808
4. Remove the spacer.

5. Install the spring.
Refer to: Spring (204-02 Rear Suspension,
2008.50 Kuga 8/2011
G1000226en

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204-02-15
Rear Suspension
204-02-15
Rear Stabilizer Bar(15 752 0)

General Equipment
Hydraulic Press
Removal
1. On booth sides.
Installation
1. NOTE: Make sure that the component is clean,
NOTE: Make sure that these components are
Refer to: Rear Stabilizer Bar Link (204-02 Rear

2.
x4
E67369
2. NOTE: Make sure that the clamp is installed to

the same orientation as when removed.
E67812
On both sides.

before removal.
E68087
2008.50 Kuga 8/2011
G1000227en

TO MODEL INDEX
204-02-16
Rear Suspension
204-02-16
E89914
3. On both sides.
E69763
4. Torque: 48 Nm
x4
E67812
5. On booth sides.
Refer to: Rear Stabilizer Bar Link (204-02 Rear
2008.50 Kuga 8/2011
G1000227en

TO MODEL INDEX
Rear Suspension
204-02-17
204-02-17
Rear Stabilizer Bar Link

Removal
2.
1. Torque: 70 Nm
2. Torque: 15 Nm
2
1
E67817
Installation
2008.50 Kuga 8/2011
G1058286en

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204-02-18
Rear Suspension
204-02-18
Rear Stabilizer Bar Bushing

Removal
1. Refer to: Rear Stabilizer Bar (204-02 Rear
Installation
1.
2008.50 Kuga 8/2011
G1000228en

TO MODEL INDEX
204-02-19
Rear Suspension
204-02-19
Wheel Knuckle LHD FWD/RHD FWD

Removal
6.
2. Refer to: Wheel Bearing and Wheel Hub (204-02

Rear Suspension, Removal and Installation).
3.
E93206
Installation
E101643
40
4.
226
E69209
E99208
2. 1. Torque: 120 Nm
2. NOTE: Only tighten the bolt finger tight at
this stage.
5.
1
E93262
E93214
2008.50 Kuga 8/2011
G1000235en

TO MODEL INDEX
204-02-20
Rear Suspension
204-02-20

3. Install the spacer. Make sure that the spacer is
in a vertical plane and raise the suspension to
the design height setting.
E93313
4. Torque: 115 Nm
5. Torque: 115 Nm
E93214
E94368
2008.50 Kuga 8/2011
G1000235en

TO MODEL INDEX
204-02-21
Rear Suspension
204-02-21

6.
E99208
7. Torque: 115 Nm
E101643

2008.50 Kuga 8/2011
G1000235en

TO MODEL INDEX
204-02-22
Rear Suspension
204-02-22
Wheel Knuckle LHD 4WD/RHD 4WD

Removal
6.

3.
E93206
Installation
E101643
40
4.
226
E69209
E99208
2. NOTE: Only tighten the bolt finger tight at
this stage.
5.
1
E93262
E93214
2008.50 Kuga 8/2011
G1000760en

TO MODEL INDEX
204-02-23
Rear Suspension
204-02-23

3. Install the spacer. Make sure that the spacer is
in a vertical plane and raise the suspension to
the design height setting.
E93313
4. Torque: 115 Nm
5. Torque: 115 Nm
E93214
E94368
2008.50 Kuga 8/2011
G1000760en

TO MODEL INDEX
204-02-24
Rear Suspension
204-02-24

6.
E99208
7. Torque: 115 Nm
E101643

2008.50 Kuga 8/2011
G1000760en

TO MODEL INDEX
Rear Suspension
204-02-25
204-02-25
Spring(15 621 0)
Special Tool(s)

204-167
Compressor, Coil Spring
2.

Torque: 70 Nm
14042
204-215
Adapter for 204-167
15111
E98878
Removal
3. Install the Special Tool(s): 204-167, 204-215
204-167
204-215
2
E98877
Installation
2008.50 Kuga 8/2011
G1000236en

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204-04-1
Wheels and Tires
204-04-1
SECTION 204-04 Wheels and Tires

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
204-04-2

Wheels and Tires (Overview).............................................................................................
Tire/wheel rim combinations...............................................................................................
Use of snow chains............................................................................................................
Tire repair kit.......................................................................................................................
Run-Flat Tires (Overview)...................................................................................................
Tires with Run-flat Properties.............................................................................................
Tire Pressure Monitoring System (TPMS) (Overview)........................................................
204-04-3
204-04-3
204-04-3
204-04-3
204-04-4
204-04-4
204-04-5
204-04-5

Wheels and Tires................................................................................................................
Symptom Chart...................................................................................................................
204-04-6
204-04-6
204-04-7

Wheel and Tire...................................................................................................................
204-04-11

TO MODEL INDEX
Wheels and Tires
204-04-2
204-04-2
SPECIFICATIONS
Tyre pressures (cold tyres) - Up to 80 km/h (50
mph)
Variant Tyre Normal load
Full load
size
Front
Rear
Front Rear
bar
(psi)
All
T135/ 4.2 (61)

90 R
17
bar
(psi)
bar
(psi)
bar
(psi)
4.2
(61)
4.2
(61)
4.2
(61)
Tyre pressures (cold tyres) - Up to 160 km/h

(100 mph)
Full load
size
Front
Rear Front Rear
Tyre pressures (cold tyres) - Continuous speed

in excess of 160 km/h (100 mph)
Full load
size
Front
Rear Front Rear
bar (psi)
bar
(psi)
bar
(psi)
bar
(psi)
All
215/
65
R16
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
All
215/
70
R16
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
All
235/
60
R16
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
All
235/
55
R17
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
bar (psi)
bar
(psi)
bar
(psi)
bar
(psi)
215/
65
R16
2.2 (32)
2.3
(33)
2.4
(35)
2.8
(41)
All
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
215/
70
R16
2.2 (32)
2.3
(33)
2.4
(35)
2.8
(41)
235/
55
RF17
All
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
235/
60
R16
2.2 (32)
2.3
(33)
2.4
(35)
2.8
(41)
235/
50
R18
All
2.3 (33)
2.3
(33)
2.4
(35)
2.8
(41)
All
235/
55
R17
2.2 (32)
2.3
(33)
2.4
(35)
2.8
(41)
235/
45
R19
All
235/
55
RF17
2.2 (32)
2.3
(33)
2.4
(35)
2.8
(41)
All
235/
50
R18
2.1 (31)
2.2
(32)
2.4
(35)
2.8
(41)
All
235/
45
R19
2.1 (31)
2.2
(32)
2.4
(35)
2.8
(41)
All
All
All
2008.50 Kuga 8/2011
G1000248en

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204-04-3
Wheels and Tires
204-04-3
Wheels and Tires Overview

Tire/wheel rim combinations
The following tire/wheel rim combinations are
available:
235/60 R16 V 6.5X16 (*)
235/55 R17 V 7.0X17 (*)
235/55 R17 V 7.5X17 (*)
235/50 R18 V 7.5X18
235/45 R19 V 8.0X19
(*) Also available as tires with run-flat capabilities.
Use of snow chains

Snow chains are only approved for use with size
235/60R16 tires.
Fine chains with a link thickness of 10mm may be
used at speeds of up to 50 km/h (please refer to
the manufacturer's instructions).
Coarser chains with a link thickness of 11 to 14
mm may be used at speeds of up to 40 km/h
(please refer to the manufacturer's instructions).
Tire repair kit

If the tires used do not have run-flat properties then
the vehicle will be equipped with a tire repair kit.
A tire repair kit is located in the spare wheel well
in the luggage compartment.
The tire repair kit consists of:
a compressor with a pressure gauge,
a lead for voltage supply via the cigar lighter,
an air hose,
tire sealant.
A tire filled with tire sealant must be replaced with
a new tire after 200 km at the latest. Read and
observe the instructions regarding the tire low
pressure sensors (see lesson 4 Tire pressure
monitoring system).
Instructions on handling and using the tire repair
kit can be found in a separate operating manual
that is enclosed with the tire repair kit.
2008.50 Kuga 8/2011
G1000249en

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Wheels and Tires
204-04-4
204-04-4
Run-Flat Tires Overview

Tires with Run-flat Properties
1
2
4
3
3
E68867
Item
Description
Item
Description
Standard tire after pressure loss
Tire with run-flat properties after pressure

loss
Wheel position with insufficient tire

pressure
Tires
Wheel position with correct tire pressure
Reinforced sidewall
In addition to the standard tires, run-flat tires are

also optionally available. These tires have a
reinforced sidewall and provide the advantage that
the tire maintains its shape to a large extent even
in the event of insufficient tire pressure. This
ensures that the vehicle handling remains stable.
Advantage:
These tires maintain their shape to a large
extent, even in the event of insufficient tire
pressure. This ensures that the vehicle handling
remains stable.
Special wheel rims (EH2) and a tire pressure
monitoring system are needed for run-flat tires.
Standard tires can also be installed on the EH2
(EH = Extended Hump) wheel rims. Tires with
run-flat properties have the same size code and
the same appearance as standard tires.
With some tires, the code RF for run-flat is included
in the tire designation, e.g. 205/55 RF 16.
2008.50 Kuga 8/2011
Tires with run-flat properties have various different

codes on the sidewall, depending on the
manufacturer.
The RFT logo
"RUNFLAT" as an additional designation
The additional designation "RSC" (RSC =
Runflat System Component)
The additional designation "SSR" (SSR = Self
Supporting Run-Flat-Tire)
The additional designation "SST" (SST = Self
Supporting Run-Flat-Tire)
WARNING: If a tire with run-flat properties
is used without air then the vehicle speed
must not exceed 80 km/h and the vehicle
must not be driven for distances in excess
of 80 km.
Note: Vehicles equipped at the factory with run-flat
tires do not feature a tire repair kit or a spare wheel.
G1000256en

TO MODEL INDEX
204-04-5
Wheels and Tires
204-04-5
Tire Pressure Monitoring System (TPMS) Overview

The tire pressure monitoring system is able to
detect loss of air in a tire at an early stage and warn
the driver. Because it can only compare the
behavior of the tires with each other, it is not
possible to draw conclusions about the absolute
tire pressure. It is also not possible to monitor the
spare tire pressure. In order for the system to
operate correctly, the tire pressures must be
regularly checked and corrected and the system
subsequently initialized (see below).
The tire pressure monitoring system used here,
depending on the equipment level, is built into the
anti-lock braking system (ABS) as an extra function
and therefore does not have its own sensors.
The ABS module determines the loss of pressure
in the tires by calculation using the wheel speed
sensors of the ABS system. If a tire loses pressure,
its diameter decreases and the speed of the wheel
therefore increases. If the ABS module detects
such a loss in pressure, it sends a signal to the
instrument cluster via the CAN bus and a warning
message is displayed in the driver information
system. The warning threshold depends among
other things on the dimension of the tires being
used, the vehicle operating conditions and the
status at the last initialization. Since neither the
absolute tire pressure nor the position of the tire is
known, after a tire pressure warning the pressure
of all the tires must be checked and the system
re-initialized. If necessary, the cause of the loss of
pressure must be investigated.
Furthermore, regular pressure checks are
necessary. The system must be initialized after a
tire is changed, winter or summer tires fitted, the
pressures corrected or adjusted to suit the vehicle
load. This can be done by the driver using the
driver information system. For further information,
see: Owners Manual.
2008.50 Kuga 8/2011
G1001290en

TO MODEL INDEX
204-04-6
Wheels and Tires
204-04-6
Wheels and Tires

Mechanical
Wheel(s)
Tire(s)
Tire pressure(s) *
Wheel nuts
Wheel studs
* Vehicles equipped with a tire deflation detection system (DDS) must be inspected for correct operation
using the Ford approved diagnostic tool.
To maximize tire performance, inspect the tires for
signs of incorrect inflation and uneven wear which
may indicate a need for balancing, rotation or
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises,
abrasions, blisters and for objects that may have
become embedded in the tread. More frequent
inspections are recommended when rapid or
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with
foreign material.
During the road test, drive the vehicle on a road

that is smooth and free of undulations. If vibration
is apparent, note and record the following:
Tire Wear Diagnosis
the speed at which the vibration occurs.

what type of vibration occurs in each speed
range.
mechanical or audible
how the vibration is affected by changes in the
following:
engine torque
vehicle speed
engine speed
type of vibration - sensitivity:
torque sensitive
vehicle speed sensitive
engine speed sensitive
Uneven wear is usually caused by either excessive

camber or excessive toe on tires.
The following explanations help isolate the source

of the vibration.
Sometimes incorrect toe settings or worn struts will

cause severe `cupping' or `scalloped' tire wear on
non-driven wheels.
Torque Sensitive
As a further visible check of tire condition, tread

wear indicators are molded into the bottom of the
tread grooves. When these indicator bands become
visible, new tires must be installed.
Severely incorrect toe settings will also cause other

unusual wear patterns.
This means that the condition can be improved or

made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Tire Vibration Diagnosis

A tire vibration diagnostic procedure always begins
with a road test. The road test and customer
interview (if available) will provide much of the
information needed to find the source of a vibration.
2008.50 Kuga 8/2011
Vehicle Speed Sensitive

This means that the vibration always occurs at the
same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
G1061329en

TO MODEL INDEX
Wheels and Tires
204-04-7
204-04-7

Engine Speed Sensitive
This means that the vibration occurs at varying
vehicle speeds when a different transmission gear
is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
to the tires.
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat

or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from axle
noise. Tire whine remains the same over a range
of speeds.
A complete road test procedure is described in
Section 100-04.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Symptom Chart
Symptom
Possible Sources
DDS warning lamp illuminated Loss of tire pressure.
Action
ADJUST the tire pressure and
reset the DDS. For additional
information REFER to the
owners guide.
DDS warning lamp illuminated The DDS reset procedure was REFER to the DDS reset
with the correct tire pressure
not carried out after adjustment
procedure. For additional
of the tire pressure.
owners guide.
DDS warning lamp not illumin- The DDS reset procedure was ADJUST the tire pressure and
ated when one or more tire(s)
carried out under incorrect tire
reset the DDS. For additional
have the incorrect tire pressure
conditions.
owners guide.
DDS reset command was not
confirmed
The DDS reset procedure was REFER to the DDS reset

not completed.
procedure. For additional
owners guide.
DDS failure warning display
Anti-lock brake system (ABS)

module.
REFER to the Ford approved

diagnostic tool.
Tire(s) show excess wear on

edge of tread
Tire(s) under-inflated.
ADJUST the tire pressure(s).
Vehicle overloaded.
CORRECT as necessary.

REFER to: Suspension System
(204-00 Suspension System
- General Information,
Tire(s) show excess wear in

center of tread
Tire(s) over-inflated.
Other excessive tire wear

concerns
Incorrect tire pressure(s).
2008.50 Kuga 8/2011
G1061329en

TO MODEL INDEX
Wheels and Tires
204-04-8
204-04-8

Symptom
Possible Sources
Action
Wheel and tire assemblies

need rotating.
ROTATE the wheel and tire

assemblies.

REFER to: Suspension System
(204-00 Suspension System
- General Information,
Vehicle overloaded.
Loose or leaking front strut and TIGHTEN or INSTALL new

spring assembly.
necessary.
Front Suspension, Disassembly and Assembly).
Wheel bearings worn.
INSTALL new wheel bearings

as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Installation).
Suspension components,
bushings and ball joints.
CHECK or INSTALL new

necessary.
Excessive lateral or radial

runout of wheel or tire.
BALANCE the wheel and tire

assemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK lateral and
radial runout of the wheel and
tire assemblies. INSTALL new
wheel and tire assemblies as
necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Wobble or shimmy affecting

wheel runout
Damaged wheel.
INSPECT the wheel rims for

damage. BALANCE the wheel
and tire assemblies. Using a
suitable dial indicator gauge
and holding fixture, CHECK
lateral and radial runout of the
wheel and tire assemblies.
INSTALL new wheel and tire
assemblies as necessary.
2008.50 Kuga 8/2011
G1061329en

TO MODEL INDEX
Wheels and Tires
204-04-9
204-04-9

Symptom
Possible Sources
Front wheel bearing.
Action
CHECK or INSTALL new wheel
bearings as necessary.
Installation).
Excessive vehicle vibration,

rough steering
Suspension components.
Vehicle vibrations from wheels Incorrect tire pressure(s).

and tires
CHECK or INSTALL new

necessary.
Wheel or tire imbalance.

assemblies.
Uneven tire wear.
INSTALL a new tire(s) as

necessary.
Brake disc imbalance.
CHECK the brake disc for

foreign material.
Water in tire(s).
REMOVE the water.
Bent wheel.
INSTALL a new wheel and tire

assembly.
Incorrectly seated tire bead.
SPIN the wheel on the vehicle.

EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
Excessive lateral or radial

runout of wheel or tire.

assemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK the lateral and
radial runout of the wheel and
tire assemblies. INSTALL new
wheel and tire assemblies as
necessary.
2008.50 Kuga 8/2011
G1061329en

TO MODEL INDEX
Wheels and Tires
204-04-10
204-04-10

Symptom
Possible Sources
Action
Foreign material between

CLEAN mounting surfaces.
wheel mounting face and hub
mounting surface.
Front wheel bearing.
CHECK or INSTALL new wheel

bearings as necessary.
Installation).
Seized wheel nuts
Corrosion.
CAUTION: Do not permit

lubricant to get on cone sets of
stud holes or on cone angle of
wheel nuts. If corrosion is
slight, wire brush away. If
corrosion is excessive,
INSTALL new wheel studs and
nuts.
If the condition persists,
LUBRICATE the first three
threads of each wheel stud with
a graphite-based lubricant.
Vehicle overloaded
2008.50 Kuga 8/2011
G1061329en

TO MODEL INDEX
Wheels and Tires
204-04-11
204-04-11
Wheel and Tire

Removal
CAUTION: Do not use heat to loosen a
seized wheel nut.
NOTE: Only tighten the nuts finger tight at this

stage.
1. Loosen: 360
x5
x5
E74934
E74933

2. Refer to: Jacking (100-02 Jacking and Lifting,
Refer to: Lifting (100-02 Jacking and Lifting,
3. Tighten the wheel nuts in the sequence shown.

Torque: 130 Nm
1
3.
x5
E74931
E74934
Installation
1.
WARNING: Make sure that the mating

faces are clean and free of corrosion
and foreign material
2008.50 Kuga 8/2011
G1000251en

TO MODEL INDEX
205-01-1
Driveshaft
205-01-1
SECTION 205-01 Driveshaft

CONTENTS
PAGE

Driveshaft....................................................................................................... (15 514 0)
205-01-2

TO MODEL INDEX
Driveshaft
205-01-2
205-01-2
Driveshaft(15 514 0)
Vehicles with 2.0L diesel engine
Removal
4.
All vehicles
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
3.
E114034
x7
Vehicles with 2.5L engine

5.
E98543
E114375
All vehicles
6.
x2
x2
x2
E114188
2008.50 Kuga 8/2011
G1070580en

TO MODEL INDEX
Driveshaft
205-01-3
205-01-3

7.
9.
1
x6
20 mm
x3
1
E101018

8.
1
E114035

10.
1
x3
x6
x3
E101687
x6
E114196
2008.50 Kuga 8/2011
G1070580en

TO MODEL INDEX
Driveshaft
205-01-4
205-01-4

11.
13.
x2
20 mm
E102254
Installation
All vehicles
1.
2
x2
E114376
All vehicles
12.
E102243
2.
E114295
E114296
2008.50 Kuga 8/2011
G1070580en

TO MODEL INDEX
Driveshaft
205-01-5
205-01-5

3.
5.

installation marks are aligned.
1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
x3
1
3
2
E101688
E114197
4.
6.
1
20 mm
E114036
2008.50 Kuga 8/2011
20 mm
E114377
G1070580en

TO MODEL INDEX
Driveshaft
205-01-6
205-01-6

All vehicles
7.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
2
1
x3
x2
1
2
E101042
8. Torque: 25 Nm
x2
x2
x2
E114188
2008.50 Kuga 8/2011
G1070580en

TO MODEL INDEX
Driveshaft
205-01-7
205-01-7

9. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
E114034

10.
11. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
E114375
All vehicles
12.
x7
E98543
2008.50 Kuga 8/2011
G1070580en

TO MODEL INDEX
205-02-1
Rear Drive Axle/Differential
205-02-1
SECTION 205-02 Rear Drive Axle/Differential

CONTENTS
PAGE

Rear Drive Axle and Differential (Component Location).....................................................
Rear Drive Axle and Differential (System Operation and Component Description)...........
General Information........................................................................................................
Driving situations............................................................................................................
Haldex clutch..................................................................................................................
General overview............................................................................................................
Operation........................................................................................................................
Design of the 3rd generation Haldex clutch....................................................................
Design of the multi-plate clutch.......................................................................................
All-wheel drive control unit..............................................................................................
Electric feed pump..........................................................................................................
Pressure control - 3rd generation Haldex clutch.............................................................
Base pressure.................................................................................................................
Increased base pressure (preload).................................................................................
Pressure build-up............................................................................................................
Design of the 4th generation Haldex clutch ...................................................................
Pressure control - 4th generation Haldex clutch.............................................................
205-02-2
205-02-6
205-02-6
205-02-6
205-02-6
205-02-6
205-02-7
205-02-7
205-02-7
205-02-9
205-02-10
205-02-10
205-02-10
205-02-11
205-02-12
205-02-13
205-02-14
205-02-14
205-02-15
GENERAL PROCEDURES
Differential Fluid Level Check.............................................................................................
Active On-Demand Coupling Fluid Level Check................................................................
205-02-17
205-02-19

Differential Case.................................................................................................................
Active On-Demand Coupling Module.................................................................................
Differential Input Shaft Seal................................................................................................
Differential Support Insulator..............................................................................................
Rear Halfshaft Seal.............................................................................................................
Drive Pinion Seal................................................................................................................
205-02-21
205-02-25
205-02-32
205-02-38
205-02-39
205-02-41

Active On-Demand Coupling Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450...............................................................
205-02-42

TO MODEL INDEX
205-02-2
205-02-2
Rear Drive Axle and Differential Component Location

Powertrain
1
3
3
4
2
6
E102416
Item
Description
Item
Description
Transmission assembly
Drive shaft
Transfer box,
Rear axle
Halfshaft - front axle
Halfshaft - rear axle
2008.50 Kuga 8/2011
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205-02-3
205-02-3

Rear axle
2
E102418
Item
Description
Rear axle differential.
Haldex controlled coupling
2008.50 Kuga 8/2011
G1076980en

TO MODEL INDEX
205-02-4
205-02-4

Mounting points - rear differential
E102861
Haldex coupling generation III/IV
E114553
Item
Description
Haldex coupling generation III
Haldex coupling generation IV
2008.50 Kuga 8/2011
G1076980en

TO MODEL INDEX
205-02-5
205-02-5

Haldex coupling generation III
2
E114554
Item
Description
Electric feed pump
Oil filter
Haldex coupling generation IV
3
2
E114555
Item
Description
Electric feed pump
Reservoir
Oil filter
2008.50 Kuga 8/2011
G1076980en

TO MODEL INDEX
205-02-6
205-02-6
Rear Drive Axle and Differential System Operation and

System Operation
General Information
The powertrain with all-wheel drive consists of the
following main components:
engine
transaxle with front axle differential
transfer box
halfshafts and driveshafts
Haldex clutch
rear axle differential
The Haldex clutch guarantees continuous variable

torque transmission to the rear axle under all
driving conditions. The Haldex clutch reacts
immediately and equally quickly with slow or fast
wheel slip.
A difference in angle of rotation of 90 between the
input and output shafts is required to build up
maximum pressure at the multi-plate clutch or to
transmit maximum torque.
The advantage of vehicles with all-wheel drive is
that they distribute the drive between all four
wheels. They therefore have a higher tractive
power. They feature improved cornering behaviour,
as the grip at all four wheels can be better utilised.
Thus, the wheels contribute to a greater degree
towards cornering stability.
A sporty driving style, in particular dynamic

cornering, demands stable cornering behaviour.
The all-wheel system distributes the propulsive
force to all four wheels and by so doing boosts
the high cornering forces so that the vehicle
makes optimum contact with the road surface.
Snow and black ice
Snow and black ice require particularly high grip.
Under these conditions, the Haldex clutch
always distributes the propulsive force to the
axle with the better traction. The all-wheel
system reacts intelligently and quickly to all
driving situations.
Trailer operation
When driving with a trailer, the trailer weight
(support load) is transmitted to the rear axle via
the towbar. This reduces the load on the front
wheels, which means they can slip. The
electronic system detects this difference and
distributes most of the propulsive force to the
rear axle.
Haldex clutch
The engine torque is transmitted from the transfer

box to the rear axle via a driveshaft. The driveshaft
is flange-mounted to the input side of the Haldex
clutch.
Driving situations
Pulling away and accelerating
When pulling away and accelerating, as much
all-wheel drive as necessary must be available
immediately in the short-term. During
acceleration, the electronic system detects slip
at the front axle. This slip is counter-controlled
and thus the propulsive force optimally
distributed to the two axes.
E100642
Cornering
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-7
205-02-7

General overview
Haldex clutches of the 3rd and 4th generations are
used in the Ford Kuga.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
electro-hydraulically controlled. Additional
information is taken into consideration during
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution
of the propulsive forces; the vehicle's driving
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally
react to every driving situation.
Compared with the previous generation, the 4th
generation Haldex clutches operate with higher
pressure and achieve shorter response times when
distributing the drive forces.
Advantages of the Haldex clutch:
Permanent all-wheel drive with
electronically-controlled multi-plate clutch
Fast response
No straining when parking and manoeuvring
Compatible with different tyres (e.g. emergency
spare wheel)
Fully combinable with driving dynamic control
systems
The driveshaft is connected to the input shaft of
the Haldex clutch. Within the Haldex clutch, the
input shaft is separated from the output shaft to
the rear axle differential by means of a multi-plate
clutch. Torque is only transmitted to the rear axle
differential when the plate assembly of the Haldex
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For
ecological driving, the torque to the rear axle is
2008.50 Kuga 8/2011
reduced to a minimum up to a throttle position of

approx. 50%. A prerequisite for this is that there is
no difference in speed in the Haldex clutch between
the input and output shafts.
Operation
3
2
5
E100645
Item
Description
Output shaft
Working piston
Plates
Ring piston pump
Control Valve
Input shaft
Within the Haldex clutch is a plate assembly and

a so-called ring piston pump with a pump plunger
and a working piston.
Fluid supply is started if there is a speed difference
between the input and output shafts.
This fluid pressure is transmitted to the working
piston and in this way the plate assembly is
compressed.
Design of the 3rd generation Haldex

clutch
G1076981en

TO MODEL INDEX
205-02-8
205-02-8
2
1
11
11
10
9
8
5
6
7
E100664
Item
Description
Item
Description
Multiplate clutch
Electric feed pump
Ring piston pump
Fluid filter
Pressure accumulator
Pressure relief valve (high pressure)
Pressure relief valve (low pressure)
Input shaft
10
Preload valve
11
High-pressure valves
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-9
205-02-9

The Haldex clutch is based on the principle of a
simple wet clutch that distributes the torque variably
between the front and rear axles.
Three components are linked within the Haldex
clutch:
A mechanical component, comprising input and

output shafts, the plate assembly (clutch) as
well as the cam plate and the roller bearing.
A hydraulic component, essentially comprising
pressure valves, a pressure accumulator, the
control valve, the ring pistons and a fluid filter.
The electronic control comprises the electric
fluid pump and the all-wheel drive control unit
with integrated pressure/temperature sensor
and an actuator motor for the control valve.
Design of the multi-plate clutch

A
3
2
1
9
10
11
6
B
12
13
7
E100662
Item
Description
Item
Description
Pump plunger assembly
Input shaft
Working piston assembly
Cam disc
Output shaft
Springs
Inner plates
Pump plunger roller
Outer plates
10
Pump plunger roller
Disc drum
11
Pump plunger
Contact plate
12
Working piston roller
13
Working piston
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-10
205-02-10

5
4
E100663
Item
Description
Electronic Control Unit
Control valve
Pressure/temperature sensor
Electrical connection CAN (controller area

network) databus
Electric feed pump connection
The all-wheel drive control unit is bolted directly to

the housing of the Haldex clutch.
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control
module. It receives signals from the PCM and from
the ABS control module via the CAN data bus. The
control module in the control unit uses these
signals to determine the fluid pressure that is
needed to actuate the clutch plates depending on
the requirement. This determines how much torque
should be transmitted to the rear wheels. All-wheel
drive is deactivated if a fault occurs in the all-wheel
drive control unit.
A preload of approx. 80 Nm is always present at
the Haldex clutch.
The temperature sensor of the Haldex clutch is

installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
and is used for adaptation to the changing viscosity
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
temperature of the hydraulic fluid is between +40
C and +60 C. If the temperature rises above 100
C, the clutch is depressurised; if the temperature
falls below 95 C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
Generation III, the stepper motor has been omitted.
The control valve is now actuated via a solenoid
valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
of pulse width modulation. The pulse width
modulation determines the position of the
adjustment spindle and thus the opening cross
section of the return hole. This is how the pressure
at the working piston of the plates is determined.
If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
open, the plates are unpressurized.
Electric feed pump

The electric feed pump is installed in the clutch
unit. It works according to the gerotor principle.
The main purpose of the feed pump is to fill the
pressure accumulator and the space behind the
pump plunger with hydraulic fluid, thereby ensuring
a fast response time of the Haldex clutch. The feed
pump used in the third generation is designed to
achieve an even higher pressure than the base
pressure of 4 bar. It is supplied with current by the
control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
Pressure control - 3rd generation

Haldex clutch
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-11
205-02-11
A
B
C
D
1
2
9
10
E100539
Item
Description
Item
Description
Barometric Pressure
Control valve
Base pressure
Increased base pressure (preload)
Electric feed pump
Filters
Drive Operating pressure

1
Plate assembly and ring piston pump
Preload valve
High-pressure valves
Pressure relief valve (low pressure)
Pressure Sensor
10
Pressure relief valve (high pressure)
Base pressure
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-12
205-02-12
E100540
Item
Description
Barometric Pressure
Base pressure
The hydraulic fluid is drawn from the sump of the

hydraulic system and directed through a filter. The
feed pump pressurises the system and pumps
hydraulic fluid into the pump plungers. This base
pressure of 4 bar presses the rollers for the pump
plungers against the cam disc. At the same time,
hydraulic fluid flows into the working piston. This
eliminates the play in the clutch plates. The Haldex
clutch can respond quickly and distribute the torque
within fractions of a second. The spring force in
the pressure accumulator determines the base
2008.50 Kuga 8/2011
Item
C
Description

pressure of 4 bar and compensates pressure
fluctuations. A compensating spring works in the
opposite direction and prevents the plate discs
becoming blocked by the force of the working
piston. This restricts the transferable torque to
approx. 7 Nm. This value can, however, deviate
slightly due to temperature and/or the difference
in speed between the input and output shafts.
G1076981en

TO MODEL INDEX
205-02-13
205-02-13
E100541
Item
Description
Barometric Pressure
Base pressure
To ensure very fast torque transmission, a higher

voltage is applied to the electric feed pump and
the control valve fully closed before the shaft-driven
pump is brought into operation. As a result, the
maximum pressure is raised above the base
pressure, and a torque of up to 80 Nm applied to
the multi-plate clutch. This achieves significantly
faster pressure build-up than with older systems
2008.50 Kuga 8/2011
Item
C
Description

(second generation). To protect the pump from
overloading, the pressure is restricted to approx.
10 bar by the pressure relief valve. The hydraulic
fluid flows back into the sump via the pressure
accumulator.
Pressure build-up
G1076981en

TO MODEL INDEX
205-02-14
205-02-14
E100542
Item
Description
Barometric Pressure
Base pressure
The pump plungers generate the operating

pressure that is controlled by the control valve as
a function of the difference in speed between the
input and output shafts. The control valve works
progressively from fully open to fully closed. The
fluid pressure can be approx. 67 bar when the
control valve is fully open. The maximum pressure
Item
C
Description

is mechanically controlled by means of the
pressure relief valve.
Design of the 4th generation Haldex

clutch
General overview
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-15
205-02-15
4
3
E115887
Item
Description
Item
Description
Fluid filter
Electric feed pump
The electric feed pump is an axial piston pump

which is more robustly designed than the gerotor
pump in the 3rd generation Haldex. The higher
feed pressure means that the ring piston pump at
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary.
The pressure accumulator on the 4th generation
Haldex is larger and is designed for the higher
pressure.
2008.50 Kuga 8/2011
The 4th generation Haldex has a larger fluid filter

which contains a non-return valve.
The all-wheel drive control unit no longer contains
a pressure sensor in the 4th generation Haldex.
Pressure control - 4th generation Haldex

clutch
G1076981en

TO MODEL INDEX
205-02-16
205-02-16

8
4
9
11
10
E114914
Item
Description
Item
Description
Haldex clutch fluid
Control valve
Inlet filter
Dished washer
Electric feed pump
Ring piston
Filters
Clutch plate pack
10
Return pressure accumulator
11
Return control valve
Full torque is available at any time on the 4th

generation Haldex clutch because the pressure is
not dependent on the difference in the speeds of
rotation. This is used for instance to activate the
Haldex clutch for better traction when moving off.
On the 4th generation Haldex clutch, the preload
function which applied 80 Nm to the plates in the
3rd generation is no longer required.
On request from the control unit and at engine
speeds above 400 rpm, the electric feed pump runs
and maintains the storage pressure at about 30
bar.
and function of the control valve. The control valve

distributes the pressure, depending on the
requirements, across its three outlet openings
(storage pressure, working pressure, return).
From the storage pressure (30 bar) and depending
on the requirements, the control valve regulates a
working pressure of 0 - 17 bar, which is applied to
the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
rear wheels. The all-wheel drive control unit
ensures the best possible performance under all
driving conditions, for all road conditions and
independent of the speed.
A pressure reducing valve acts as a control valve,

allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position
2008.50 Kuga 8/2011
G1076981en

TO MODEL INDEX
205-02-17
205-02-17
GENERAL PROCEDURES
Differential Fluid Level Check

Materials
Name
Specification
Rear Axle Oil SAE 80W- WSP-M2C197-A / 4U7J90 F

M2C197-AA
3. Material: Rear Axle Oil SAE 80W-90 F

(WSP-M2C197-A / 4U7J-M2C197-AA)
transmission fluid
Correct the rear axle oil level if neccessary.
24 ml ~ 1 mm

Operation).
2.
E104195
E104196
2008.50 Kuga 8/2011
G1087340en
205-02-18

TO MODEL INDEX
205-02-18
GENERAL PROCEDURES
4. Torque: 43 Nm
E104195
2008.50 Kuga 8/2011
G1087340en

TO MODEL INDEX
205-02-19
205-02-19
GENERAL PROCEDURES
Active On-Demand Coupling Fluid Level Check

Materials
7.
Name
Specification
Transmission Oil AWD
8U7J-8708687-AA
Activation
Operation).
6. NOTE: This component does not have a drain
plug because the fluid does not need to be
drained or changed.
E102723
8. Material: Transmission Oil AWD

(8U7J-8708687-AA) transmission fluid
Correct the oil level if neccessary.
24 ml ~ 1 mm
5 mm
E102724
2008.50 Kuga 8/2011
G1087341en
205-02-20

TO MODEL INDEX
205-02-20
GENERAL PROCEDURES
9. Torque: 43 Nm
E102723
2008.50 Kuga 8/2011
G1087341en

TO MODEL INDEX
205-02-21
205-02-21
Differential Case
General Equipment
Cable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive

Halfshafts, Removal and Installation).
4. Refer to: Driveshaft (205-01 Driveshaft,

5.
2.
1
x3
x6
E114256
E101687
6.
3.
x2
E114255
E101709
2008.50 Kuga 8/2011
G1061458en

TO MODEL INDEX
205-02-22
205-02-22

All vehicles
All vehicles
7.
9.
x2
E101710

E101713
30
x2
Installation
All vehicles
1.
30
mm
x2
E101711
2008.50 Kuga 8/2011
E101714
G1061458en

TO MODEL INDEX
205-02-23
205-02-23

2.
4. Torque: 80 Nm
x2
E101709
5.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
E101712
All vehicles
x3
3. Torque: 80 Nm
x2
3
2
E101710
2008.50 Kuga 8/2011
E101688
G1061458en

TO MODEL INDEX
205-02-24
205-02-24

6.
x2
E114255
7. Torque: 80 Nm
E114256

All vehicles
10. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
2008.50 Kuga 8/2011
G1061458en

TO MODEL INDEX
205-02-25
205-02-25
Active On-Demand Coupling Module

Materials
Name
Specification
8U7J-8708687-AA
Removal
All vehicles
4.

Operation).


3.
x3
x6
E101687
x2
5.
x2
E102531
x4
E102544
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-26
205-02-26

7.
6.
x7
E114375
E98543
8.
x2
x2
E114188
9.
x6
x3
1
E101018
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-27
205-02-27

10.
12.
1
20 mm
x3
x6
E114196
13.
E114376
11.
x4
E114254
E114295
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-28
205-02-28

All vehicles
Installation
14.
All vehicles
E102545
E102554

2. Torque: 25 Nm
x2
x4
E102544
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-29
205-02-29

3.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm

5. Torque: 25 Nm
x3
1
x4
E114254
6.
1
3
2

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
E101688
4. Torque: 25 Nm
x3
1
x2
x2
3
2
E114197
7.
E102531
E114296
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-30
205-02-30

8.
9.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
2
1
20 mm
x3
x2
1
2
E101042
10. Torque: 25 Nm
E114377
x2
x2
x2
E114188
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-31
205-02-31

11. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
E114375
12.
x7
E98543
All vehicles
13. Refer to: Active On-Demand Coupling Fluid
Level Check (205-02 Rear Drive
Axle/Differential, General Procedures).
Refer to: Differential Fluid Level Check (205-02
Procedures).
2008.50 Kuga 8/2011
G1076971en

TO MODEL INDEX
205-02-32
205-02-32
Differential Input Shaft Seal

204-093
Remover/Installer, Lower Arm
Bushing

205-078-01
Pad)
14032
1504801
303-249
Remover, Crankshaft Timing
Pulley
205-072
Universal Flange Holding
Wrench
21132
15030A
205-078
Remover, Drive Pinion Seal
Puller
15048
Removal
All vehicles
4.

Operation).
3.
E114034
x7
5.
E98543
2008.50 Kuga 8/2011
G1076972en

TO MODEL INDEX
205-02-33
205-02-33
x2
x2
x2
E114188
7.
6.
x6
20 mm
x3
1
E101018
E114035
2008.50 Kuga 8/2011
G1076972en

TO MODEL INDEX
205-02-34
205-02-34

8.
303-249
E102496
E114295
Vehicles with manual transmission
9.
12.
1
x3
x6
x3
E101687
x6
E114196
10. Special Tool(s): 205-072, 303-249
13. Special Tool(s): 205-072, 303-249
303-249
303-249
205-072
E102495
2008.50 Kuga 8/2011
205-072
E102495
G1076972en

TO MODEL INDEX
205-02-35
205-02-35

Installation
All vehicles
204-093
E114331
All vehicles
15. Special Tool(s): 205-078, 205-078-01
E102517
2. Special Tool(s): 205-072, 303-249

Torque: 150 Nm
205-078-01
303-249
205-078
205-072
E102516
E102500
2008.50 Kuga 8/2011
G1076972en

TO MODEL INDEX
205-02-36
205-02-36

3.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
All vehicles
5.
1
20 mm
x2
3
2
E101688

4.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
E114036
6.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
x3
1
2
1
x2
x3
1
x2
2
1
2
E114197
E101042
2008.50 Kuga 8/2011
G1076972en

TO MODEL INDEX
205-02-37
205-02-37

7. Torque: 25 Nm
x2
x2
x2
E114188
8. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
E114034

Procedures).
10.
x7
E98543
2008.50 Kuga 8/2011
G1076972en

TO MODEL INDEX
205-02-38
205-02-38
Differential Support Insulator

Special Tool(s)
Special Tool(s)
308-762
Remover/Installer, Bush RDU
204-598
Hydraulic Cylinder 10t
E102678
E75373
204-598-03
Adapter for 204-598
Materials
Name
Transmission Oil 75W
FE
Specification
WSS-M2C200-D2 /
7U7J-M2C200-BA
E103784
Removal
1. Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
2. Special Tool(s): 204-598, 204-598-03, 308-762
204-598
Installation
1. Special Tool(s): 204-598, 204-598-03, 308-762
Material: Transmission Oil 75W FE
(WSS-M2C200-D2 / 7U7J-M2C200-BA)
transmission fluid
204-598-03
308-762
308-762
204-598-03
E102574
204-598
E102575
2. Refer to: Differential Case (205-02 Rear Drive

Axle/Differential, Removal and Installation).
2008.50 Kuga 8/2011
G1076973en

TO MODEL INDEX
205-02-39
205-02-39
Rear Halfshaft Seal

303-395
Installer, Crankshaft Seal

Tire Lever
21171
Removal
Installation
2. General Equipment: Tire Lever
303-395
E102535

E102537
E102536
2008.50 Kuga 8/2011
G1080736en

TO MODEL INDEX
205-02-40
205-02-40

303-395
E102538

Procedures).
2008.50 Kuga 8/2011
G1080736en

TO MODEL INDEX
205-02-41
205-02-41
Drive Pinion Seal

Special Tool(s)
Special Tool(s)
308-643
Installer, Input Shaft Seal
303-293
Remover, Crankshaft Seal
21143
E65343
Removal
Operation).
2. Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
Installation
1.
CAUTION: Take extra care not to

damage the seal.
308-643
303-293
E102547
2. Refer to: Active On-Demand Coupling Module

(205-02 Rear Drive Axle/Differential, Removal
and Installation).
303-293
E102546
2008.50 Kuga 8/2011
G1357281en

TO MODEL INDEX
205-02-42
205-02-42
Active On-Demand Coupling Vehicles With: 5-Speed Automatic

Transaxle - AW55 AWD/6-Speed Automatic Transaxle 6DCT450
205-072
Universal Flange Holding
Wrench

303-249
Remover, Crankshaft Timing
Pulley
21132
15030A
Puller
Materials
Name
Specification
8U7J-8708687-AA
Disassembly
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-43
205-02-43

Operation).
5.

3.
E124778
6.

escaping fluid.
x2
E124749
7.
E114257
4.

escaping fluid.
E124748
2008.50 Kuga 8/2011
E128365
G1268328en

TO MODEL INDEX
205-02-44
205-02-44

8.
9.
x7
E98543
E114375
10.
x2
x2
x2
E114188
11.
x6
x3
1
E101018
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-45
205-02-45

12.
14.
1
20 mm
x3
x6
E114196
15. Special Tool(s): 205-072, 303-249
303-249
E114376
13.
205-072
E102495
E114295
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-46
205-02-46

Assembly

E114331
17.

escaping fluid.
E124752
19. Torque: 6 Nm
x2
x2
E124753
E124753
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-47
205-02-47

20. Special Tool(s): 205-072, 303-249
Torque: 150 Nm
22.
303-249
E114296
23.
205-072
E102500
21.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
20 mm
x3
1
x2
3
2
E114377
E114197
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-48
205-02-48

24.

1. Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
2
1
x3
x2
1
2
E101042
25. Torque: 25 Nm
x2
x2
x2
E114188
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-49
205-02-49

26. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
29.
E128367
30. Torque: 6 Nm
E114375
27.
x7
x2
E124749

E98543
28. 1. NOTE: Make sure that a new component is

installed.
E124750
E124780
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-02-50
205-02-50

32. Torque: 6 Nm
E124748
33.
E114257
34. Refer to: Active On-Demand Coupling Fluid

Level Check (205-02 Rear Drive
Axle/Differential, General Procedures).
2008.50 Kuga 8/2011
G1268328en

TO MODEL INDEX
205-04-1
Front Drive Halfshafts
205-04-1
SECTION 205-04 Front Drive Halfshafts

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
205-04-2

Front Drive Halfshafts.........................................................................................................
205-04-3
205-04-3

Front Halfshaft LH.......................................................................................... (14 320 0)
Front Halfshaft RH LHD 4WD/RHD 4WD.................................................. (14 321 0)
Inner Constant Velocity (CV) Joint Boot......................................................... (14 336 0)
Outer Constant Velocity (CV) Joint Boot........................................................ (14 338 0)
Halfshaft Bearing................................................................................................................
205-04-5
205-04-16
205-04-27
205-04-30
205-04-31

TO MODEL INDEX
205-04-2
205-04-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Specificat
ions
Outer Constant Velocity Joint
Grease
WSS-M1C
259-A1
Specificat
ions
Inner Constant Velocity Joint Grease WSS-M1C
259-A1
Capacity
Description
Driveshaft Joint Grease Fill Capacity

Inner (Grams)
Outer (Grams)
160
180
2.0 L Duratorq
2.5 L Duratec
Item
Nm
lb-ft
lb-in
2.0 L Duratorq - Intermediate shaft center bearing

bracket to engine block bolts - 2WD (M10x 30)
48
35

48
35

bracket to engine block bolt - 4WD (M10x 40)
60
44
2.5 L Duratec - Intermediate shaft center bearing

48
35
2.5 L Duratec - Intermediate shaft center bearing

bracket to engine block bolt - 4WD (M10x 40)
60
44
2008.50 Kuga 8/2011
G1081400en

TO MODEL INDEX
205-04-3
205-04-3

NOTE: New front wheel drive halfshafts should not
be installed unless disassembly and inspection
reveals unusual wear.
1. Inspect front wheel driveshaft joint boots for
evidence of cracks, tears or splits.
NOTE: While inspecting the front wheel driveshaft
CV joint boots, watch for indentations (dimples) in
the boot convolutions. If an indentation is observed,
it must be removed.
3. Inspect for inboard CV joint stub shaft pilot

bearing housing seal leakage at the front wheel
driveshaft CV joint.
4. Make sure front axle wheel hub retainer is the
correct prevailing torque type.
5. The silicone front wheel driveshaft CV joint boot
will sweat during operation, causing a light film
of grease to show on the outside of the front
wheel driveshaft CV joint boot. This condition
is normal.
NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
2. Inspect the underbody for any indication of

6. If the concerns remain after the inspection,
grease splatter in the vicinity of the front wheel
determine the symptoms and go to the Symptom
driveshaft CV joint boots outboard and inboard
Chart. For additional Noise, Vibration and
locations, which is an indication of front wheel
Harshness (NVH). REFER to Section 100-04
driveshaft CV joint boot and/or front wheel
[Noise, Vibration and Harshness].
driveshaft CV joint boot clamp damage.
Symptom Chart
Symptom
Possible Sources
Action
Clicking, Popping or Grinding
Noises While Turning
Inadequate or contaminated
INSPECT, CLEAN and
lube in outboard/inboard front
LUBRICATE as necessary.
wheel driveshaft CV joint.
Another component contacting INSPECT and REPAIR as
driveshaft assembly.
necessary.
Wheel bearings, brakes,
suspension or steering
components.
Vibration at Highway Speeds
INSPECT and REPAIR as

necessary. REFER to
Section 204-00 [Suspension
System - General Information]
/ 206-00 [Brake System General Information] / 211-00
[Steering System - General
Information].
Out of balance front wheels or REPAIR or INSTALL new as

tires.
necessary. REFER to
Section 204-04 [Wheels and
Tires].
Out-of-round tires.
REPAIR or INSTALL new as

necessary. REFER to
Section 204-04 [Wheels and
Tires].
Incorrectly seated outboard

REPAIR or INSTALL new as
front wheel driveshaft CV joint
necessary.
in front wheel hub.
REFER to Halfshaft Disassemblv and Assembly in this
section.
2008.50 Kuga 8/2011
G17442en

TO MODEL INDEX
205-04-4
205-04-4

Symptom
Shudder Vibration During
Acceleration.
Possible Sources
Action
Excessively high CV joint oper- CHECK ride height, VERIFY

ating angles caused by incorcorrect spring rate and CHECK
rect ride height.
items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
Excessively worn or damaged INSPECT and INSTALL new
inboard front wheel driveshaft
as necessary.
joint or outboard front wheel
driveshaft joint.
Halfshaft Joint Pullout
Inboard driveshaft bearing

retainer circlip missing or not
correctly seated in differential
side gear.
INSPECT and REPAIR or

INSTALL new as necessary.
Engine/transaxle assembly
mispositioned.
CHECK engine mounts for

damage or wear. REPAIR or
INSTALL new as necessary.
Frame rail or strut tower out of CHECK underbody dimensions.

position or damaged.
REFER to REFER to
Section 501-00 [Body System
- General Information].
Front suspension components CHECK for worn bushings or
worn or damaged.
bent components (front stabilizer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
2008.50 Kuga 8/2011
G17442en

TO MODEL INDEX
205-04-5
205-04-5
Front Halfshaft LH(14 320 0)

204-159

211-020
13006
14039
308-782
Remover, Driveline
204-602
E115823
E62067
204-605
Joint
Puller
Tire Lever
Removal
E63772

204-609
Gaiter
E75372
205-071-01
Pad)
15026A01
205-775
Protector, Halfshaft Seal
E99184
E47098
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-6
205-04-6

Refer to: Wheel and Tire (204-04 Wheels and
4.

E101039
E99269
5.

E100801
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-7
205-04-7

6.
9.

E67589
E99197
7.
211-020
E132305
E99198
8. If equipped.
11.
E125279
E97635
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-8
205-04-8

15.
204-605
E97732
E99255
13.
16. If equipped.
x7
E99196
E98543
204-609
E81908
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-9
205-04-9

Vehicles with 6-speed manual transaxle
(MMT6)
Vehicles with 6-speed manual transmission

(M66)
17.
18.

escaping fluid.
1.
2.
3.
4.

escaping fluid.
Install the Special Tool(s): 308-782
General Equipment: Tire Lever
Remove the Special Tool(s): 308-782
308-782
205-775
308-782
E132274
205-775
E132306
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-10
205-04-10

Vehicles with automatic transaxle
All vehicles
20. CAUTIONS:
The inner constant velocity (CV) joint
must not be bent more than 18.
The outer constant velocity (CV) joint
Special Tool(s): 204-159, 204-605
E132267
90
204-159
4
204-605
E132272
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-11
205-04-11

21.

Special Tool(s): 205-071-01
General Equipment: Puller
E132268
205-071-01
E132270
Installation
Torque: 45 Nm
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-12
205-04-12
204-602
E132271
2. NOTE: Make sure that a new component is

installed.
3. CAUTIONS:
E132269
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-13
205-04-13

90
4
204-159
2
204-605
1
5
205-775
50
E132304
4. Torque: 90 Nm
204-605
E97732
E99255
204-609
E81908
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-14
205-04-14

NOTE: Only tighten the nut finger tight at this
stage.
7.
E132273
11. If equipped.
Torque: 8 Nm
E132381
8. Torque: 83 Nm
E125279
12. Torque: 5 Nm
E97635
9.
WARNING: Make sure that a new nut is

installed.
Torque: 80 Nm
E132305
E99197

2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-15
205-04-15

13.
16.
17. If equipped.
x7
E67589
E98543
14. Torque: 120 Nm

19. Lower the Vehicle.
Torque: 270 Nm
x2
E132307
15.
E99195
E101039
2008.50 Kuga 8/2011
G1076961en

TO MODEL INDEX
205-04-16
205-04-16
Front Halfshaft RH LHD 4WD/RHD 4WD(14 321 0)

204-159
Removal
14039
204-602
E62067
204-605
Joint
E99184
E63772
204-609
Gaiter

E75372
205-071-01
Pad)
15026A01
211-020
E102112
13006
Puller
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-17
205-04-17

4.
5.

E102106
E100801
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-18
205-04-18

6.
9.

E67589
E99197
7.
211-020
E132305
E99198
8. If equipped.
11.
E125279
E102113
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-19
205-04-19

15.
204-605
E102114
E99255
13.
16. If equipped.
x7
E99196
E98543

(MMT6)
17.
x2
204-609
E102115
E132330
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-20
205-04-20

All vehicles
18.
19.

escaping fluid.
CAUTIONS:
x2

Special Tool(s): 204-159, 204-605
E132332
3
1
90
204-159
204-605
E132335

Special Tool(s): 205-071-01
General Equipment: Puller
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-21
205-04-21
205-071-01
E132270
Installation
Torque: 45 Nm
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-22
205-04-22
204-602
E132271
2. CAUTIONS:
2008.50 Kuga 8/2011

Special Tool(s): 204-159, 204-605
G1076962en

TO MODEL INDEX
205-04-23
205-04-23
90
204-159
204-605
E132336
3. Torque: 90 Nm

(MMT6)
installed.
installed.
Torque: 6 Nm
installed.
E99255
Torque: 6 Nm
4. Torque: 25 Nm
5. Torque: 25 Nm
5
1
E132329
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-24
205-04-24

8.

installed.
Torque: 10 Nm
installed.
Torque: 10 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm
E132381
9. Torque: 83 Nm
E132331
All vehicles
E102113
204-605
10.
WARNING: Make sure that a new nut is

installed.
Torque: 80 Nm
E102114
204-609
E99197
E102115

2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-25
205-04-25

NOTE: Only tighten the nut finger tight at this
stage.
14.
E67589
E132273
15. Torque: 120 Nm

12. If equipped.
Torque: 8 Nm
x2
E125279
13. Torque: 5 Nm
E132307
16.
E132305
E102106
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-26
205-04-26

17.
18. If equipped.
x7
E98543

Torque: 270 Nm
E99195
2008.50 Kuga 8/2011
G1076962en

TO MODEL INDEX
205-04-27
205-04-27
Inner Constant Velocity (CV) Joint Boot(14 336 0)

204-169
Clamping Tool, Boot
Retaining Clamp
2. Discard the grease.
14044
308-046
Installer, Transmission
Extension Housing
Bushing/Seal
16016
E105704
Puller
Materials
Name
Grease FD-R
3.
Specification
WSS-M1C259-A1 /
3M5J-M1C259-AA
Removal
1. Remove the halfshaft.
Refer to: Front Halfshaft LH (205-04 Front Drive
Refer to: Front Halfshaft RH - LHD 4WD/RHD
4WD (205-04 Front Drive Halfshafts, Removal
and Installation).
E78743
E78744
2008.50 Kuga 8/2011
G1076988en

TO MODEL INDEX
205-04-28
205-04-28

Installation
3.
NOTE: Make sure that the component is clean,

303-362
3
2
E113013
4. Material: Grease FD-R (WSS-M1C259-A1 /

3M5J-M1C259-AA) grease
1
1
2
E114434
2.
E112739
E78746
2008.50 Kuga 8/2011
G1076988en

TO MODEL INDEX
205-04-29
205-04-29

5. 1. Release any trapped air.
General Equipment: Flat-bladed screwdriver
1
7. Install the halfshaft.

Refer to: Front Halfshaft LH (205-04 Front Drive
and Installation).
0 mm
25 mm
E114410

Torque: 21 Nm
204-169
E105711
2008.50 Kuga 8/2011
G1076988en

TO MODEL INDEX
205-04-30
205-04-30
Outer Constant Velocity (CV) Joint Boot(14 338 0)

Special Tool(s)
204-169
Clamping Tool, Boot
Retaining Clamp

Torque: 21 Nm
14044
204-169
Removal
1. Remove the inner CV joint boot.
Refer to: Inner Constant Velocity (CV) Joint Boot
(205-04 Front Drive Halfshafts, Removal and
Installation).
2.
E77542
3. Install the inner CV joint boot.

Refer to: Inner Constant Velocity (CV) Joint Boot
(205-04 Front Drive Halfshafts, Removal and
Installation).
E77185
Installation
1. Fill the CV joint with grease.
Insert a small screwdriver under the boot
seat to allow the air to escape.
E77333
2008.50 Kuga 8/2011
G1076989en

TO MODEL INDEX
205-04-31
205-04-31
Halfshaft Bearing
204-169
Clamping Tool, Boot
Retaining Clamp

303-255
Installer, Timing Cover Seal
14044
21136
205-080
Installer, Differential Bearing
Hydraulic Press
Materials
Name
205080
Grease FD-R
Specification
WSS-M1C259-A1 /
3M5J-M1C259-AA
205-310
Remover, Bearing/Gear
TI15091
Removal
2.
1.
E113013
E112738
2008.50 Kuga 8/2011
G1209151en

TO MODEL INDEX
205-04-32
205-04-32

2. Material: Grease FD-R (WSS-M1C259-A1 /

3M5J-M1C259-AA) grease
205-310
E112938
E112739
3. 1. Release any trapped air.
Installation
1. Special Tool(s): 205-080, 303-255
General Equipment: Flat-bladed screwdriver

1
205-080
303-255
0 mm
4
E112939
E112740
2008.50 Kuga 8/2011
25 mm
G1209151en

TO MODEL INDEX
205-04-33
205-04-33

204-169
E112741
2008.50 Kuga 8/2011
G1209151en

TO MODEL INDEX
205-05-1
Rear Drive Halfshafts
205-05-1
SECTION 205-05 Rear Drive Halfshafts

CONTENTS
PAGE

Rear Halfshaft.....................................................................................................................
205-05-2

TO MODEL INDEX
205-05-2
205-05-2
Rear Halfshaft
308-759
Remover, Rear Driveshaft

Tire Lever
Transmission Jack
Materials
Name
E100143
Sealant LGN
Specification
WSK-M2G349-A8 /
9U7J-M2G349-AA
Cable Ties
Removal
1. On both sides.
2. On both sides.
5. On both sides.
6. On both sides.
x4
E101639
E101661

4.
7. On both sides.

On both sides.
General Equipment: Cable Ties
E101640
E100132
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205-05-3
205-05-3

8. On both sides.
Vehicles built up to 06/2009

308-759/2
E114252
E101646
9. On both sides.
E101641
308-759/1
10. On both sides.
E101647
E101643
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TO MODEL INDEX
205-05-4
205-05-4

16. On both sides.
Vehicles built 07/2009 onwards

50
mm
E121184
All vehicles
E101645
308-759/1
E102119
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205-05-5
205-05-5

Installation
1. On both sides.
3. NOTE: Only tighten the bolt finger tight at this

stage.
On both sides.
E101641
40
226
E101644
E69209
2. On both sides.
Torque: 115 Nm
5. On both sides.
General Equipment: Transmission Jack
E101643
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205-05-6
205-05-6
E93313
6. On both sides.
Torque: 130 Nm

1. Spacer
8. On both sides.
Torque: 5 Nm
E101642
E114252
2008.50 Kuga 8/2011
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TO MODEL INDEX
205-05-7
205-05-7

9. On both sides.
Material: Sealant LGN (WSK-M2G349-A8 /
9U7J-M2G349-AA) adhesive
11. On both sides.

Torque: 110 Nm
x4
E101639
12. On both sides.

E120924
13.
10. On both sides.

On both sides.
Torque: 110 Nm
x2
E101662
14. On both sides.
E101640
Material: Sealant LGN (WSK-M2G349-A8 /

9U7J-M2G349-AA) adhesive
Torque: 50 Nm
E101661
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TO MODEL INDEX
205-05-8
205-05-8

15. On both sides.
Procedures).
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206-00-1
Brake System - General Information
206-00-1
SECTION 206-00 Brake System - General Information

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
Front Brake Disc Specification........................................................................................
Rear Disc Brake Specification........................................................................................
206-00-2
206-00-2
206-00-2

Brake System (Overview)...................................................................................................
Brake System.....................................................................................................................
206-00-3
206-00-3

Brake System.....................................................................................................................
Road Test...........................................................................................................................
Pinpoint Tests.....................................................................................................................
Component Tests................................................................................................................
Brake System Check..........................................................................................................
Brake Booster Functional Test............................................................................................
206-00-4
206-00-4
206-00-4
206-00-10
206-00-17
206-00-17
206-00-17
GENERAL PROCEDURES
Brake Disc Runout Check.............................................................................. (12 221 0)
Check.................................................................................................................................
Component Bleeding..........................................................................................................
Brake System Bleeding......................................................................................................
Brake System Draining and Filling................................................................. (12 154 0;
12 154 4)
Brake System Pressure Bleeding.......................................................................................
206-00-20
206-00-20
206-00-22
206-00-27
206-00-32
206-00-35

TO MODEL INDEX
206-00-2
206-00-2
SPECIFICATIONS
Specification
Super DOT 4 brake fluid
ESD-M6C57-A /
WSSM6C57- A2
Front Brake Disc Specification

mm
Brake disc diameter
300
New brake disc nominal thickness
25
Worn brake disc discard thickness *
23
Maximum brake disc thickness variation

Worn brake pad discard thickness**
Maximum brake disc runout (installed)
0.025
1.5
0.015
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Rear Disc Brake Specification

Description
Brake disc diameter
mm
302
New brake disc nominal thickness
11
Worn brake disc discard thickness *
Maximum brake disc thickness variation
0.025
Worn brake pad discard thickness **
1.5
Maximum brake disc runout (installed)
0.1
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
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206-00-3
206-00-3
Brake System Overview

Brake System
E96610
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206-00-4
206-00-4
Brake System
performance guidelines to make good comparisons
and detect performance concerns.
General Equipment
Pressure/vacuum gauge set
The brake system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.

NOTE: Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
Mechanical
Tire pressure(s)
Wheels and tires
Fluid leak(s)
Electrical
Electrical
connector(s)
Wiring harness(s)
Switch(es)

concern is found, correct the case (if possible)
4. If the cause if not visually evident, verify the
Road Test
Carry out a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of
the brake system operation and accepted general
2008.50 Kuga 8/2011
An experienced technician will always establish a

route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth
and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system. If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
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206-00-5
206-00-5

narrow the cause to a specific component or
Symptom Chart
Symptom
Brakes pull or drift
condition.
Possible Sources
Action
Worn or damaged brake shoes INSTALL new brake shoes or

or brake pads and linings.
brake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
Abnormal wear or distortion of INSTALL a new front brake
front brake disc.
disc.
REFER to: Brake Caliper (20603 Front Disc Brake,
Incorrect rear brake adjustment.
ADJUST the parking brake

cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
Incorrect wheel alignment

adjustment.

REFER to: (204-00 Suspension
System - General Information)
Front Toe Adjustment (General
Procedures),
Rear Toe Adjustment (General
Procedures).
Incorrect wheel bearing preload ADJUST or INSTALL a new

adjustment.
wheel bearing.
Installation).
Grease or fluid on the brake
shoes or brake pads; glazed
linings.
INSTALL new brake shoes or

brake pads.
and Installation).
Stuck or seized wheel cylinders INSTALL a new wheel cylinder

or brake calipers.
or brake caliper.
REFER to: Brake Caliper (20604 Rear Disc Brake, Removal
and Installation).
The red brake warning indicator Low brake fluid level.
is always on
2008.50 Kuga 8/2011
FILL the reservoir. CHECK the

brake and clutch system for
leaks including brake fluid in
the brake booster.
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206-00-6
206-00-6

Symptom
Possible Sources
Action
Leaking brake master cylinder INSTALL a new brake master

primary piston cup.
cylinder.
REFER to: Brake Master
Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation,
Parking brake control not fully FREE UP and ADJUST the
released.
parking brake cable.
INSTALL new components as
necessary.
Malfunctioning anti-lock braking REFER to: Anti-Lock Control
system (ABS).
(206-09 Anti-Lock Control,
Shorted indicator circuit.
Vibration when the brakes are Grease or fluid on the brake

applied
shoes or brake pads; glazed
linings.
REFER to: Instrument Cluster

(413-01 Instrument Cluster,
brake pads.
and Installation).

or brake pads.
brake pads.
and Installation).
Loose caliper mounting bolt(s). TIGHTEN the caliper mounting
bolt(s).
Excessive brake disc thickness
variation or brake disc runout.
Wheels and tires.
CHECK the tires. BALANCE or

INSTALL new tires as necessary.
REFER to: Wheels and Tires
Loose or missing wheel hub

bolts.
TIGHTEN or INSTALL new

wheel hub bolts as necessary.
Worn or damaged brake drums CARRY OUT a brake disc

or brake discs.
runout check.
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206-00-7
206-00-7

Symptom
Pedal goes down fast
Possible Sources
Action
Low brake fluid level.
FILL the reservoir. CHECK the

brake and clutch system for
leaks including brake fluid in
the brake booster.
Leak in the hydraulic system.
REPAIR the leak. CHECK the

entire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
Brake System Bleeding
(General Procedures),
Brake System Pressure
Bleeding (General Procedures),
Component Bleeding (General
Procedures).
Air in the system.
CHECK for leaks. BLEED the

brake system. REFER to: (20600 Brake System - General
Information)
Procedures).
Brake disc brake knock back CARRY OUT a brake disc

(Brake pads push the brake
runout check.
caliper piston back into the
brake caliper. Caused by
excessive brake disc lateral
runout or loose wheel bearings.)
Worn brake shoes or brake
pads.

brake pads.
and Installation).
Worn brake master cylinder

piston cups or scored cylinder
bore.
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TO MODEL INDEX
206-00-8
206-00-8

Symptom
Pedal eases down slowly
Possible Sources
Air in the system.
Action
BLEED the brake system.
REFER to: Brake System
Pressure Bleeding (206-00
Brake System - General
REFER to: (206-00 Brake
Procedures).
Pedal is low or feels spongy
Malfunctioning brake master

cylinder.
Low engine vacuum
(stationary).

pads.

brake pads.
and Installation).
Air in the system.
CHECK for leaks. BLEED the

brake system. REFER to: (20600 Brake System - General
Information)
Procedures).
Brake lockup during light brake Glazed or worn brake shoes or INSTALL new brake shoes or
pedal force
brake pads.
brake pads.
and Installation).
Excessive or erratic pedal

travel
Brake booster.
Low engine vacuum.
GO to Pinpoint Test C.

pads.

brake pads.
and Installation).
Wheel bearings
2008.50 Kuga 8/2011
CARRY OUT a brake disc

runout check.
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206-00-9
206-00-9

Symptom
Brake drag
Possible Sources
Incorrectly adjusted parking
brake or brake pedal switch
Action
ADJUST the parking brake
cable or switch
Brake booster.
REFER to brake booster operation check in this procedure.
Seized wheel cylinder or brake INSTALL a new wheel cylinder

caliper.
or brake caliper.
Seized brake caliper slide pins. INSTALL a new brake caliper.
Seized parking brake cables.
INSTALL new parking brake

cables.
Parking brake not fully

released.
Check the parking brake leaver

position and make sure there
are no obstructions.
Brake hose incorrectly fitted.
Check all brake hose(s) for

correct fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installation)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Excessive brake pedal effort
Worn or contaminated brake

shoes or brake pads.

brake pads.
and Installation).
2008.50 Kuga 8/2011
Malfunctioning vacuum pump

(diesel).
INSTALL a new brake vacuum

pump.
Disconnected or damaged
brake booster vacuum pipe.
CONNECT or INSTALL a new

brake booster vacuum pipe as
necessary.
Brake booster.
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206-00-10
206-00-10

Symptom
Brake noise
Possible Sources
Action

or brake pads.
brake pads.
and Installation).
Brake booster.
GO to Pinpoint Test E.
Slow or incomplete brake pedal Brake booster.

return
Seized brake pedal pivot.
GO to Pinpoint Test F.
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM

1 Pump the foot brake rapidly five times.
Does the brake pedal height build up and then
hold?
Yes
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
No
GO to A2.
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206-00-11
206-00-11

TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS

1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
Are any leaks present?
Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
Procedures),
No
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
Was a concern found?
Yes
INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
No
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION

1 Depress the brake pedal.
Does the pedal ease down slowly?
Yes
GO to B2.
No
Refer to the Brake Master Cylinder
Component Test in this procedure.
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TO MODEL INDEX
206-00-12
206-00-12

TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS

1 Check for external brake system leaks.
Are any leaks present?
Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
Procedures),
No
GO to B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
Was a concern found?
Yes
INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
No
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster
check valve.
Does air pass through the valve?
Yes
INSTALL a new brake booster check valve.
No
GO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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206-00-13
206-00-13

TEST CONDITIONS
2 Using a suitable vacuum gauge, check the
vacuum pressure.
Is the vacuum pressure above 40.5 kPa (0.4
bar) with the brake booster non-operational?
Yes
No
INSTALL a new brake booster check valve
vacuum hose. TEST the system for normal
operation.
PINPOINT TEST C : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
TEST CONDITIONS
C1: CHECK THE BRAKE BOOSTER

1 Check the brake booster push rod alignment
and pedal travel.
Is the push rod and pedal travel OK?
Yes
TEST the brake pedal application. GO to
Pinpoint Test D.
No
INSTALL a new brake booster. TEST the
PINPOINT TEST D : EXCESSIVE BRAKE PEDAL EFFORT
TEST CONDITIONS
D1: CHECK BRAKE APPLICATION

1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
Does the brake pedal hold?
Yes
GO to D2.
No
GO to D3.
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206-00-14
206-00-14

TEST CONDITIONS
D2: CHECK THE BRAKE BOOSTER FOR LEAKS

1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the
brakes. Two or more brake applications should
be power assisted.
Does the brake booster work?
Yes
No
GO to D4.
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
Did the pedal move freely?
Yes
No
INSTALL new brake pedal bushings. TEST
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster
check valve.
Does air pass through the valve?
Yes
INSTALL a new brake booster check valve.
No
GO to D5.
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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206-00-15
206-00-15

TEST CONDITIONS
2 Using a suitable vacuum gauge, check the
vacuum pressure.
Is the vacuum pressure above 40.5 kPa (0.4
bar) with the brake booster non-operational?
Yes
GO to D6.
No
INSTALL a new vacuum hose and fittings.
D6: CHECK THE BRAKE BOOSTER
1 Check the brake booster. REFER to the Brake
Booster Operation Check in this procedure.
Is the brake booster OK?
Yes
No
PINPOINT TEST E : BRAKE NOISE
TEST CONDITIONS
E1: CHECK FOR PEDAL NOISE

1 Run the engine at idle for 10 seconds or longer.
2 Apply the brake pedal and listen for noise.
3 Compare results with a known good system.
Was a noise present?
Yes
GO to E2.
No
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206-00-16
206-00-16

TEST CONDITIONS
E2: CHECK THE BRAKE BOOSTER

1 Check the brake booster push rod alignment
and travel.
Is the push rod and pedal travel OK?
Yes
BLEED the brake system. REFER to: (206-00
Brake System - General Information)
Procedures),
No
PINPOINT TEST F : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST CONDITIONS
F1: CHECK FOR BRAKE PEDAL RETURN

1 Run the engine at approximately 1200 rpm
whilst making several brake applications.
2 Pull the brake pedal upwards with approximately
44.5 N (10 lbs) force.
3 Release the brake pedal and measure the
distance to the floor panel and note the reading.
4 Make a hard brake application.
5 Release the brake pedal and measure the
distance to the floor panel and note the reading.
6 Compare the measurements.
Did the brake pedal return to its original position?
Yes
No
GO to F2.
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206-00-17
206-00-17

TEST CONDITIONS
F2: CHECK FOR BRAKE PEDAL BINDING

1 Check the brake pedal for free operation.
Did the brake pedal operate freely?
Yes
No
INSTALL new brake pedal bushings. TEST
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may
have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
the reservoir fluid level is actually dropping. Locate
and repair the external leak. If the fluid level drops
and no external leak can be found, check for a
brake master cylinder bore end seal leak.
Brake System Check

Brake Pedal Reserve Check
Where a low brake pedal or the feel of a
bottomed-out condition exists, check for brake
pedal reserve.
1. Operate the engine at idle with the transaxle in
the NEUTRAL position.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for the vacuum to replenish
the brake booster.
NOTE: This increased resistance may feel like
something has bottomed out.
4. Apply the brake pedal until it stops moving
downward or an increased resistance to the
pedal travel occurs.
2008.50 Kuga 8/2011
5. Hold the brake pedal in the applied position and

raise the engine speed to approximately 2000
rpm.
NOTE: The additional movement of the brake pedal
is the result of the increased engine manifold
vacuum which exerts more force on the brake
booster during engine rundown. This means that
additional stroke is available in the brake master
cylinder and the brake system is not bottoming out.
6. Release the accelerator pedal and observe that
the brake pedal moves downward as the engine
returns to idle speed.
Brake Booster Functional Test

Inspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
their connections should be correctly secured and
in good condition with no holes and no collapsed
areas. Inspect the check valve on the brake booster
for damage.
Brake Booster Operation Check

1. Check the hydraulic brake system for leaks or
low fluid.
2. With the transaxle in the NEUTRAL position,
stop the engine and apply the parking brake.
Apply the brake pedal several times to exhaust
all the vacuum in the system.
3. With the engine turned off and the vacuum in
the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the vacuum
system is operating, the brake pedal will tend
to move downward under constant foot
pressure. If no motion is felt, the vacuum
booster system is not functioning.
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206-00-18
206-00-18

4. Remove the vacuum hose from the brake
booster. Manifold vacuum should be available
at the brake booster end of the hose with the
engine at idle speed and the transaxle in the
NEUTRAL position. Make sure that all unused
vacuum outlets are correctly capped, hose
connectors are correctly secured and vacuum
hoses are in good condition. When it is
established that manifold vacuum is available
to the brake booster, connect the vacuum hose
to the brake booster and repeat Step 3. If no
downward movement of the brake pedal is felt,
install a new brake booster.
5. Operate the engine a minimum of 10 seconds
at approximately 1200 rpm. Stop the engine and
let the vehicle stand for 10 minutes. Then, apply
the brake pedal with approximately 89 N (20 lb)
force. The pedal feel (brake application) should
be the same as that noted with the engine
operating. If the brake pedal feels hard (no
power assist), install a new vacuum check valve
and then repeat the test. If the brake pedal still
feels hard, install a new brake booster. If the
brake pedal movement feels spongy, bleed the
brake system. REFER to: (206-00 Brake System
- General Information)
Procedures),
Brake Master Cylinder

Usually, the first and strongest indicator of anything
wrong with the braking system is a feeling through
the brake pedal. In diagnosing the condition of the
brake master cylinder, check pedal feel as
evidence of a brake concern. Check for the red
brake warning indicator illumination and the fluid
level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal
and are not indications that the brake master
cylinder is in need of service.
Modern brake systems are not designed to
produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be
2008.50 Kuga 8/2011
compared to pedal efforts of another vehicle, of

the same model and year.
During normal operation of the brake pedal, the
fluid level in the reservoir will rise during brake
pedal application and fall during release. The
net fluid level (i.e., after brake pedal application
and release) will remain unchanged.
A trace of brake fluid will exists on the brake
booster shell below the master cylinder
mounting flange. This results from the normal
lubricating action of the master cylinder bore
end seal.
The fluid level will fall with brake shoe and lining
wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make
sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are indicators
that something could be wrong with the braking
system. The diagnostic procedure and techniques
use brake pedal feel, warning indicator illumination
and low brake fluid level as indicators in diagnosing
braking system concerns. The following conditions
are considered abnormal and indicate that the
brake master cylinder is in need of service.
The brake pedal goes down fast. This could be
caused by an external or internal leak.
The brake pedal eases down slowly. This could
be caused by an external or internal leak.
The brake pedal is low and or feels spongy. This
condition may be caused by no fluid in the brake
master cylinder reservoir, reservoir cap vent
holes clogged or air in the hydraulic system.
The brake pedal effort is excessive. This may
be caused by a bind or obstruction in the pedal
or linkage, clogged fluid control valve or
insufficient booster vacuum.
The rear brakes lock up during light pedal force.
This may be caused by incorrect tire pressures,
grease or fluid on the brake shoes and linings,
damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or
contaminated brake pressure control valves.
The brake pedal effort is erratic. This condition
could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly
installed brake shoes and linings.
The red brake warning indicator is ON. This may
be caused by low fluid level, ignition wire routing
G1058975en

TO MODEL INDEX
206-00-19
206-00-19

too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test

1. Check the fluid in the brake master cylinder
reservoir. Fill the brake master cylinder reservoir
if low or empty.
2. Observe the fluid level in the brake master
cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting)
Apply the brakes with a minimum of 445 N (100
lb) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir
condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the brake
master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the brake
master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
2008.50 Kuga 8/2011
G1058975en

TO MODEL INDEX
206-00-20
206-00-20
GENERAL PROCEDURES
Brake Disc Runout Check(12 221 0)

Dial Indicator Gauge (Metric)
205-069 (15-046)
2. Slowly rotate the wheel and tire and note the

readings.
206-003
15046
205-069
Holding Fixture, Dial Indicator

Gauge
205-070 (15-022A)
205-070
TIE0036133
15022A
Holding Fixture, Dial Indicator

Gauge (Disc Brake)
206-003 (12-003)
12003
2. NOTE: Using paint or typing correction fluid,

mark the position of the wheel in relation to
the wheel hub.
Remove the wheel and tire.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
3. Remove the brake pads.
Micrometer 0-125 mm
Check
1. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner face of the brake
disc (wheel and tire shown removed for
clarity).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10 mm
from the outer edge.
For additional information, refer to: Brake

Caliper - Detach (206-03 Front Disc Brake,
Removal and Installation)
/ Brake Caliper - Detach (206-04 Rear Disc
Brake, Removal and Installation).
4. Install the wheel nuts and tighten the wheel
nuts to 10 Nm, to hold the brake disc in
place.
5. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner and outer faces of
the brake disc (outer face measurement
shown).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10 mm
from the outer edge.
2008.50 Kuga 8/2011
G1076535en

TO MODEL INDEX
206-00-21
206-00-21
GENERAL PROCEDURES
2. Slowly rotate the brake disc and note the
readings.
9. If the brake disc runout measurement without

the wheel and tire fitted is outside the
specification, check the wheel hub face
runout.
206-003
205-070
and tire rotation and checking process until

the measurement is within specification.
10. NOTE: Using paint or typing correction

fluid, mark the position of the brake disc in
relation to the wheel hub.
Remove the brake disc.
205-069
TIE0035481
6. NOTE: If any of the readings vary by more

than 0.015 mm or the brake disc thickness
is less than the specified minimum, a new
brake disc must be installed and the brake
disc runout re-checked.
Check the brake disc thickness variation.
11. NOTE: Make sure that the wheel hub face

is clean and free of rust and foreign
material.
NOTE: Re-position the dial indicator gauge so that
it contacts the wheel hub approximately 10 mm
from the outer edge of the wheel hub.
Check the wheel hub face runout.
Slowly rotate the wheel hub and note the
readings.
For additional information, refer to:

Specifications (206-00 Brake System General Information, Specifications).
Using a suitable micrometer, measure the
brake disc thickness at eight positions, 45
degrees apart and approximately 15 mm from
the outer edge of the brake disc.
TIE0035482
12. If the wheel hub runout exceeds 0.03 mm,

install a new wheel hub.
MPU1201004
7. If all the brake disc runout measurements

and the thickness variation are within the
specifications, check the wheel balance.
For additional information, refer to: Wheel

Hub (204-01 Front Suspension, Removal
and Installation)
/ Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and
Installation).
13. If the wheel hub face runout is within
specification, install a new brake disc.
8. If just the brake disc runout measurement

with the wheel and tire fitted exceeds the
specification, the wheel and tire must be
rotated through 90 degrees in relation to the
brake disc and the brake disc runout
re-checked.
If the brake disc runout measurement still
exceeds the specification, repeat the wheel
2008.50 Kuga 8/2011
G1076535en

TO MODEL INDEX
206-00-22
206-00-22
GENERAL PROCEDURES
Component Bleeding
General Equipment
Fluid Container
Vehicles without stability assist

3.
Bleeding
a level surface.
1. Refer to: Brake System Health and Safety
Vehicles with stability assist

2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
E86914
4.
CAUTION: The brake fluid reservoir

must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
2008.50 Kuga 8/2011
G1464506en

TO MODEL INDEX
206-00-23
206-00-23
GENERAL PROCEDURES
5.
6. General Equipment: Fluid Container
E139455
E139454
7. Loosen: 180
2008.50 Kuga 8/2011
G1464506en

TO MODEL INDEX
206-00-24
206-00-24
GENERAL PROCEDURES
E139456
8. Operate the brake pedal fully (pumping brake

fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
2008.50 Kuga 8/2011
9. Continue operating the brake pedal until air-free

fluid is being pumped into the bleed jar.
10. Refer to: Specifications (206-00 Brake System
G1464506en

TO MODEL INDEX
206-00-25
206-00-25
GENERAL PROCEDURES
E139915
11. With the brake pedal fully depressed tighten the

bleed nipple.
Torque: 9 Nm
2008.50 Kuga 8/2011
G1464506en

TO MODEL INDEX
206-00-26
206-00-26
GENERAL PROCEDURES
E139456
13.
12.
E139455
2008.50 Kuga 8/2011
E86914
G1464506en

TO MODEL INDEX
206-00-27
206-00-27
GENERAL PROCEDURES

General Equipment
Fluid Container
a level surface.

3.


E86914
4.
CAUTION: The brake fluid reservoir

must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
E139915
2008.50 Kuga 8/2011
G1057428en

TO MODEL INDEX
206-00-28
206-00-28
GENERAL PROCEDURES
5.
6.
CAUTION: Make sure that the pressure

within the brake system does not
exceed 1 bar.
General Equipment: Fluid Container
E139455
E139454
7. Loosen: 180
2008.50 Kuga 8/2011
G1057428en

TO MODEL INDEX
206-00-29
206-00-29
GENERAL PROCEDURES
E139456
8. Operate the brake pedal fully (pumping brake

fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
2008.50 Kuga 8/2011
9. Continue operating the brake pedal until air-free

fluid is being pumped into the bleed jar.
G1057428en

TO MODEL INDEX
206-00-30
206-00-30
GENERAL PROCEDURES
E139915
11. With the brake pedal fully depressed tighten the

bleed nipple.
Torque: 9 Nm
2008.50 Kuga 8/2011
G1057428en

TO MODEL INDEX
206-00-31
206-00-31
GENERAL PROCEDURES
E139456
14.
12.
E139455
E86914
13. Repeat the procedure for the remaining brake

lines.
2008.50 Kuga 8/2011
G1057428en

TO MODEL INDEX
206-00-32
206-00-32
GENERAL PROCEDURES
Brake System Draining and Filling(12 154 0; 12 154 4)

General Equipment
Fluid Container

18. On both sides.
Draining
16.
E139455
19. On both sides.

E86914
E139454
20. On both sides.

Loosen: 180
2008.50 Kuga 8/2011
G1420093en

TO MODEL INDEX
206-00-33
206-00-33
GENERAL PROCEDURES
E139456
22. On both sides.

Torque: 9 Nm
21.
x20
1
2
E137083
2008.50 Kuga 8/2011
G1420093en

TO MODEL INDEX
206-00-34
206-00-34
GENERAL PROCEDURES
E139456
Filling
23. Refer to: Brake System Bleeding (206-00 Brake
Procedures).
Refer to: Brake System Pressure Bleeding
(206-00 Brake System - General Information,
Refer to: Component Bleeding (206-00 Brake
Procedures).
2008.50 Kuga 8/2011
G1420093en

TO MODEL INDEX
206-00-35
206-00-35
GENERAL PROCEDURES
Brake System Pressure Bleeding

General Equipment
Brake/Clutch System Pressure Bleeder/Filler
a level surface.

3.


E86914

E139915
5.
CAUTION: Make sure that the pressure

within the brake system does not
exceed 1 bar.
2008.50 Kuga 8/2011
Using the brake/clutch system pressure

bleeder/filler, pressure bleed the system in
accordance with the manufacturer's instructions.
General Equipment: Brake/Clutch System
Pressure Bleeder/Filler
G1057429en

TO MODEL INDEX
206-00-36
206-00-36
GENERAL PROCEDURES
6.

x4
E139916
E139915
8.
E86914
2008.50 Kuga 8/2011
G1057429en

TO MODEL INDEX
206-03-1
Front Disc Brake
206-03-1
SECTION 206-03 Front Disc Brake

CONTENTS
PAGE

Brake Pads..................................................................................................... (12 234 0)
Brake Caliper.................................................................................................. (12 243 0)
Front Brake Flexible Hose..................................................................................................
206-03-2
206-03-4
206-03-5

TO MODEL INDEX
Front Disc Brake
206-03-2
206-03-2
Brake Pads(12 234 0)

CAUTION: Make sure that no load is
Torque: 28 Nm
Special Tool(s)
206-005
Retractor, Brake Caliper
Piston
12014
Materials
Name
Specification
Brake Fluid - Super

DOT4
WSS-M6C57-A2
Lubricating Paste
WSS-M12A4-A2 / 1C1J19584-BA
E94825
5.
Removal
E100312
3.
6.
E100314
E100313
4.
WARNING: The brake caliper housing

Torx bolts must not be removed.
2008.50 Kuga 8/2011
G1001203en

TO MODEL INDEX
206-03-3
Front Disc Brake
206-03-3

Installation
1. NOTE:
Material: Lubricating Paste (WSS-M12A4-A2 /
1C1J-19584-BA) grease
206-005
1
E94902
E117895
2. Material: Lubricating Paste (WSS-M12A4-A2 /

1C1J-19584-BA) grease
E117451
4. Depress the brake pedal, check the brake fluid

level in the brake fluid reservoir and top up as
necessary with brake fluid.
Material: Brake Fluid - Super DOT4
(WSS-M6C57-A2) brake fluid
2008.50 Kuga 8/2011
G1001203en

TO MODEL INDEX
206-03-4
Front Disc Brake
206-03-4
Brake Caliper(12 243 0)

General Equipment
Hose Clamp(s)
Removal
3. General Equipment: Hose Clamp(s)
Loosen: 90
NOTE: This step is only necessary when

Refer to: Front Brake Flexible Hose (206-03
Front Disc Brake, Removal and Installation).
Installation
Procedures).
E94932
4. Refer to: Brake Pads (206-03 Front Disc Brake,

5. Torque: 22,5 Nm
E95017
6.
WARNING: Make sure that the brake

hose is not twisted and is correctly
located.
2008.50 Kuga 8/2011
G1001204en

TO MODEL INDEX
Front Disc Brake
206-03-5
206-03-5
Front Brake Flexible Hose

Removal
CAUTION:
Refer to: Brake System Health and Safety

2. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
are sealed.
1. Torque: 15 Nm
4. Torque: 23 Nm
2
3
1
4
E99419
Installation
2. Refer to: Component Bleeding (206-00 Brake
Procedures).
2008.50 Kuga 8/2011
G1001206en

TO MODEL INDEX
206-04-1
Rear Disc Brake
206-04-1
SECTION 206-04 Rear Disc Brake

CONTENTS
PAGE

Brake Pads..................................................................................................... (12 238 0)
Brake Caliper.................................................................................................. (12 253 0)
Rear Brake Flexible Hose...................................................................................................
206-04-2
206-04-4
206-04-5

TO MODEL INDEX
Rear Disc Brake
206-04-2
206-04-2
Brake Pads(12 238 0)

4. CAUTIONS:
Special Tool(s)
Make sure that the component is not

bent.
206-012
Retractor, Rear Brake Caliper
Piston
Make sure that the clips are correctly

located.
NOTE: Note the position of each component
before removal.
12006
Materials
Name
Brake Fluid - Super
DOT4
Specification
WSS-M6C57-A2
1
2
Removal
E70029

3.

Torque: 35 Nm
E70030
Installation
1. 1.
E100131
2008.50 Kuga 8/2011
CAUTION: Make sure that the mating

faces are clean and free of foreign
material.
Remove the adhesive foil from the rear of
the outer brake pad.
G1001207en

TO MODEL INDEX
Rear Disc Brake
206-04-3
206-04-3
2
1
E139523

3. Depress the brake pedal, check the brake fluid
2008.50 Kuga 8/2011
G1001207en

TO MODEL INDEX
Rear Disc Brake
206-04-4
206-04-4
Brake Caliper(12 253 0)

5.
General Equipment
Hose Clamp(s)

are sealed.
NOTE: Note the position of each component
before removal.
Materials
Name
Brake Fluid - Super
DOT4
Specification
WSS-M6C57-A2
Removal
E70111

Refer to: Rear Brake Flexible Hose (206-04
Rear Disc Brake, Removal and Installation).
3.
Installation
Procedures).
1
E70112
3.
4. 1. General Equipment: Hose Clamp(s)
2. Torque: 28 Nm
3. Torque: 35 Nm
3

material.
Depress the brake pedal, check the brake fluid
x2

E70110
2008.50 Kuga 8/2011
G1001208en

TO MODEL INDEX
Rear Disc Brake
206-04-5
206-04-5
Rear Brake Flexible Hose

Removal
CAUTION:
Refer to: Brake System Health and Safety

2. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
are sealed.
1. Torque: 15 Nm
E99425
2008.50 Kuga 8/2011
G1001210en

TO MODEL INDEX
206-04-6
Rear Disc Brake
206-04-6

3. Torque: 28 Nm
E99426
Installation
2. Refer to: Component Bleeding (206-00 Brake
Procedures).
2008.50 Kuga 8/2011
G1001210en

TO MODEL INDEX
206-05-1
Parking Brake and Actuation
206-05-1
SECTION 206-05 Parking Brake and Actuation

CONTENTS
PAGE

Parking Brake (Overview)...................................................................................................
Overview.............................................................................................................................
Parking brake cable............................................................................................................
Parking brake control..........................................................................................................
206-05-2
206-05-2
206-05-2
206-05-3

Parking Brake.....................................................................................................................
Symptom Chart...................................................................................................................
Pinpoint Tests.....................................................................................................................
206-05-4
206-05-4
206-05-4
206-05-5
GENERAL PROCEDURES
Parking Brake Cable Adjustment........................................................................................
206-05-9

Parking Brake Control.................................................................................... (12 664 0)
Parking Brake Rear Cables................................................................................................
206-05-11
206-05-12

TO MODEL INDEX
206-05-2
206-05-2
Parking Brake Overview

Overview
E103685
Item
Description
Parking brake cable
Parking brake control
The following components may be renewed

separately:
Parking brake cable
Parking brake cable
E103686
2008.50 Kuga 8/2011
G1058325en

TO MODEL INDEX
206-05-3
206-05-3

The following instructions must be followed when
removing, installing or renewing the parking brake
cable:
If the parking brake cable is removed, installed
or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
E103687
The following instructions must be followed when

removing, installing or renewing the parking brake
lever:
If the parking brake lever is removed, installed
or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
Procedures).
2008.50 Kuga 8/2011
G1058325en

TO MODEL INDEX
206-05-4
206-05-4
Parking Brake
parking brake system.
Mechanical
Parking brake
control
REFER to: Parking
Brake Control
(206-05 Parking
Brake and Actuation, Removal
and Installation).
Cable and conduit

Electrical
Parking brake
warning circuit.
REFER to: Instrument Cluster (41301 Instrument
Cluster, Diagnosis
and Testing).
REFER to: Parking

Brake Rear
Cables (206-05
Parking Brake and
Actuation,
Removal and
Installation).
Symptom Chart
Symptom Chart
Symptom
Possible Sources
Action
The parking brake will not apply Parking brake control.

Cable and conduit.
The parking brake will not hold Parking brake control.

the vehicle
The parking brake will not

release
2008.50 Kuga 8/2011
Parking brake control.

Cable and conduit.
G1063696en

TO MODEL INDEX
206-05-5
206-05-5

Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
TEST CONDITIONS
A1: CHECK PARKING BRAKE CABLE ADJUSTMENT

1 Release the parking brake and measure the gap
between the lever and the caliper.
Is the gap 1.2mm?
1.2 mm
Yes
Vehicle OK
No
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
E83778
A2: CHECK FUNCTION OF PARKING BRAKE ON BRAKE CALIPER

1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to: Lifting (100-02 Jacking and Lifting,
With the aid of another technician, release the
parking brake and check the operation of the
brake cables and levers.
Are the left-hand (LH) and right-hand (RH)
parking brake levers moving a similar distance?
Yes
CHECK the other causes such as conventional
brake system components. REPAIR or
No
REFER to: Brake Caliper (206-04 Rear Disc
2008.50 Kuga 8/2011
G1063696en

TO MODEL INDEX
206-05-6
206-05-6

TEST CONDITIONS
A3: CHECK FOR WORN BRAKE SHOES OR PADS

1 Inspect the brake shoes or pads for excessive
wear.
REFER to: Specifications (206-00 Brake System
Are the brake shoe linings or brake pads OK?
Yes
GO to A4.
No
INSTALL new brake shoes or pads.
REFER to: Brake Pads (206-04 Rear Disc
A4: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
Are the parking brake cables and conduits OK?
Yes
CHECK for other causes such as loose
parking brake control or conventional brake
system components.
No
REPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal
operation.
PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE
TEST CONDITIONS
B1: CHECK PARKING BRAKE CONTROL

1 Raise and support the vehicle on a lift with the
parking brake fully applied.
With the aid of another technician, release the
parking brake and check the operation of the
brake cables and levers.
Did the parking brake release?
Yes
CHECK the other causes such as conventional
brake system components. REPAIR or
No
GO to B2.
2008.50 Kuga 8/2011
G1063696en

TO MODEL INDEX
206-05-7
206-05-7

TEST CONDITIONS
B2: CHECK PARKING BRAKE CABLES

1 Loosen the parking brake cable tension.
Rotate the rear wheels by hand.
Did the rear wheels turn freely?
Yes
INSTALL a new parking brake control.
REFER to: Parking Brake Control (206-05
Parking Brake and Actuation, Removal and
Installation).
No
GO to B3.
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and
conduit from the rear brake cable and conduit
at the equalizer.
Rotate the rear wheels by hand.
Did the rear wheels turn freely?
Yes
INSTALL a new front parking brake cable and
conduit.
REFER to: Parking Brake Rear Cables (20605 Parking Brake and Actuation, Removal
and Installation).
No
GO to B4.
2008.50 Kuga 8/2011
G1063696en

TO MODEL INDEX
206-05-8
206-05-8

TEST CONDITIONS
B4: CHECK REAR PARKING BRAKE CABLES

1 Disconnect the parking brake at the rear brakes,
one at a time.
Rotate the wheel affected by the disconnected
parking brake.
Did the wheel turn freely?
Yes
INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes.
REFER to: Parking Brake Control (206-05
Parking Brake and Actuation, Removal and
Installation)
/ Brake Caliper (206-04 Rear Disc Brake,
No
REFER to: Brake System (206-00 Brake
System - General Information, Diagnosis
and Testing).
2008.50 Kuga 8/2011
G1063696en

TO MODEL INDEX
206-05-9
206-05-9
GENERAL PROCEDURES
Parking Brake Cable Adjustment

1. 1. Fully apply the parking brake.
2. Fully release the parking brake control.
3. NOTE: This step is only necessary if the parking

brake cable was removed.
2.
1. Torque: 2 Nm
E92650
E102065
2008.50 Kuga 8/2011
G1001211en

TO MODEL INDEX
206-05-10
206-05-10
GENERAL PROCEDURES
4. 2. Loosen the parking brake cable adjustment
nut to the end of the parking brake cable
thread.
P
E102067

6. NOTE: This step requires the aid of another
technician.
1. Insert a 1.2 mm feeler gauge between the
parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment
nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check
for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut to
the end of the parking brake cable thread,
clean the parking brake cables and repeat
the parking brake cable adjustment
procedure.
5. If brake drag is still felt after, repeat the
adjustment using a 1.0 mm feeler gauge. If
brake drag is still felt, loosen the parking
brake adjustment nut and reduce the feeler
gauge measurement by 0.2 mm each time,
until no brake drag can be felt at the rear
wheels and tires.
1.2 mm
E83778
2008.50 Kuga 8/2011
G1001211en

TO MODEL INDEX
206-05-11
206-05-11
Parking Brake Control(12 664 0)

Installation
Removal
1. 2. Torque: 35 Nm
3. NOTE: Only tighten the nut finger tight at this
stage.
2. Release the parking brake.

3.
2
2
2
4
3
1
2
E93328
3
E93308
2. Refer to: Parking Brake Cable Adjustment

Procedures).
2008.50 Kuga 8/2011
G1058318en

TO MODEL INDEX
206-05-12
206-05-12
Parking Brake Rear Cables

Removal

1. Fully release the parking brake control.
4x4
2.
5. Torque: 25 Nm
x4
x2
3
E92650
3. Loosen the parking brake cable adjustment nut

to the end of the parking brake cable thread.
E101187
4x2
6. Torque: 25 Nm
x4
E92651
E101189
2008.50 Kuga 8/2011
G1072319en

TO MODEL INDEX
206-05-13
206-05-13

All vehicles
9.
7. 1. Torque: 25 Nm
2. Torque: 5 Nm
2
x2
x4
2
3
E101192
10.
E101191
8. Torque: 5 Nm
x4
2
1
E70349
E101190
2008.50 Kuga 8/2011
11. Torque: 2 Nm
G1072319en

TO MODEL INDEX
206-05-14
206-05-14
x4
3
1
E101193
Installation
2. Refer to: Parking Brake Cable Adjustment
Procedures).
2008.50 Kuga 8/2011
G1072319en

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206-06-1
Hydraulic Brake Actuation
206-06-1
SECTION 206-06 Hydraulic Brake Actuation

CONTENTS
PAGE

Brake Pedal and Bracket RHD 4WD/RHD FWD...........................................................
Brake Master Cylinder 2.5L Duratec (147kW/200PS) - VI5....................... (12 343 0)
206-06-2
206-06-5

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206-06-2
206-06-2
Brake Pedal and Bracket RHD 4WD/RHD FWD

Removal

2.
E101395
2008.50 Kuga 8/2011
G1065459en

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206-06-3
206-06-3

3. Torque: 9 Nm
4.

x3
E101396
E123785
2008.50 Kuga 8/2011
G1065459en

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206-06-4
206-06-4

5.

Torque: 24 Nm
x4
E101510
Installation
1. CAUTIONS:
Make sure that the brake booster push
rod is correctly located.
Make sure that the brake pedal remains
in the rest position.
2008.50 Kuga 8/2011
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206-06-5
206-06-5
Brake Master Cylinder 2.5L Duratec (147kW/200PS) VI5(12 343 0)

Left-hand drive vehicles
Removal
2. 1. Connect one end of a suitable piece of clear
plastic pipe to the brake caliper bleed nipple
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until no more brake
fluid comes through the bleed nipple.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the
opposite side brake caliper.
3.

are sealed.
1. Torque: 18 Nm
2. NOTE: Make sure that new components are
installed.
Torque: 25 Nm
E86914
2008.50 Kuga 8/2011
G1174985en

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206-06-6
206-06-6
E114838

4.

are sealed.
1. Torque: 18 Nm
installed.
Torque: 25 Nm
2008.50 Kuga 8/2011
G1174985en

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206-06-7
206-06-7
1
2
E114811
Installation
Procedures).
2008.50 Kuga 8/2011
G1174985en

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206-07-1
Power Brake Actuation
206-07-1
SECTION 206-07 Power Brake Actuation

CONTENTS
PAGE

Brake Booster 2.5L Duratec (147kW/200PS) - VI5, RHD 4WD/RHD FWD. (12 451 0)
Brake Vacuum Hose 2.5L Duratec (147kW/200PS) - VI5..............................................
Brake Vacuum Pump 2.5L Duratec (147kW/200PS) - VI5........................ (12 414 0)
206-07-2
206-07-7
206-07-9

TO MODEL INDEX
206-07-2
206-07-2
Brake Booster 2.5L Duratec (147kW/200PS) - VI5, RHD

4WD/RHD FWD(12 451 0)


Refer to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
2. Torque: 24 Nm
4.
Removal
x4
1
E69829
E65299
5. Torque:
Stage 1: 10 Nm
Stage 2: 25 Nm
x6
E99866
6.
2008.50 Kuga 8/2011
G1185955en

TO MODEL INDEX
206-07-3
206-07-3
E94502
7. Torque: 48 Nm
8. Torque: 10 Nm
E93370
E95359
9. Torque: 80 Nm
E66822
2008.50 Kuga 8/2011
G1185955en

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206-07-4
206-07-4

2. Torque: 10 Nm
1
2
E99862
11. Torque: 80 Nm
2008.50 Kuga 8/2011
G1185955en

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206-07-5
206-07-5
E95358
12. Torque: 18 Nm
E99865
2008.50 Kuga 8/2011
G1185955en

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206-07-6
206-07-6

13. Torque: 8 Nm
E99864
14.
E99863
Installation
booster pushrod is correctly located.
2008.50 Kuga 8/2011
G1185955en

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206-07-7
206-07-7
Brake Vacuum Hose 2.5L Duratec (147kW/200PS) - VI5

Removal

1.
E113948

2.
2008.50 Kuga 8/2011
G1174983en

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206-07-8
206-07-8
x3
E113949
Installation
2008.50 Kuga 8/2011
G1174983en

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206-07-9
206-07-9
Brake Vacuum Pump 2.5L Duratec (147kW/200PS) VI5(12 414 0)

Removal
1. Torque: 10 Nm
x2
E74256
Installation
2008.50 Kuga 8/2011
G543409en

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206-09A-1
Anti-Lock Control
206-09A-1
SECTION 206-09A Anti-Lock Control

CONTENTS
PAGE

Anti-Lock Control (Component Location)...........................................................................
Anti-Lock Control (Overview)..............................................................................................
Anti-lock Brake System......................................................................................................
Anti-Lock Control (System Operation and Component Description)..................................
206-09A-2
206-09A-3
206-09A-3
206-09A-4
206-09A-4

Anti-Lock Control................................................................................................................
206-09A-5

TO MODEL INDEX
206-09A-2
Anti-Lock Control
206-09A-2
Anti-Lock Control Component Location

NOTE:
Refer to: Brake System (206-00 Brake System General Information, Description and Operation).
E96610
2008.50 Kuga 8/2011
G1001298en

TO MODEL INDEX
206-09A-3
Anti-Lock Control
206-09A-3
Anti-Lock Control Overview

Anti-lock Brake System
Refer to: Anti-Lock Control - Stability Assist (206-09
Anti-Lock Control - Stability Assist, Description
and Operation).
2008.50 Kuga 8/2011
G1001218en

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206-09A-4
Anti-Lock Control
206-09A-4
Anti-Lock Control System Operation and Component Description

System Operation
Refer to: Anti-Lock Control - Stability Assist (206-09
Anti-Lock Control - Stability Assist, Description
and Operation).
2008.50 Kuga 8/2011
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Anti-Lock Control
206-09A-5
206-09A-5
Anti-Lock Control
Refer to Wiring Diagrams Section 206-09A, for
General Equipment

Mechanical
Electrical
Wheel speed
Fuse(s)
sensor(s)
Electrical
Wheel speed sensor
connector(s)
ring(s)
Wiring harness(s).
Anti-lock brake
system (ABS)
module
2008.50 Kuga 8/2011
G1058976en

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206-09B-1
Anti-Lock Control - Stability Assist
206-09B-1
SECTION 206-09B Anti-Lock Control - Stability Assist

CONTENTS
PAGE

Anti-Lock Control - Stability Assist (Component Location).................................................
206-09B-2
Anti-Lock Control - Stability Assist (Overview)...................................................................
206-09B-3
Overview............................................................................................................................. 206-09B-3
Testing the brakes on a roller dynamometer - 4X4 vehicles only................................... 206-09B-4
ABS/ESP module or hydraulic control unit (HCU).............................................................. 206-09B-4
Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor............................................................................................................................... 206-09B-4
Front wheel sensor............................................................................................................. 206-09B-5
Rear wheel sensor.............................................................................................................. 206-09B-5
Opto-electronic steering wheel rotation sensor.................................................................. 206-09B-5
ESP switch......................................................................................................................... 206-09B-6
Anti-Lock Control - Stability Assist (System Operation and Component Description)........
206-09B-7
System Diagram................................................................................................................. 206-09B-7
System Operation............................................................................................................... 206-09B-8
PRINCIPLES OF OPERATION....................................................................................... 206-09B-9
Component Description...................................................................................................... 206-09B-11
Opto-electronic steering wheel rotation sensor.............................................................. 206-09B-?
ABS/ESP module or hydraulic control unit (HCU).......................................................... 206-09B-?
ESP switch...................................................................................................................... 206-09B-?
Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor........................................................................................................................... 206-09B-?
Front wheel sensor......................................................................................................... 206-09B-?
Rear wheel sensor.......................................................................................................... 206-09B-?
Hydraulic Control Unit (HCU).............................................................................................
Stability Assist Module........................................................................................................
Front Wheel Speed Sensor................................................................................................
Rear Wheel Speed Sensor.................................................................................................
Yaw Rate Sensor................................................................................................................
206-09B-16
206-09B-19
206-09B-21
206-09B-22
206-09B-23

TO MODEL INDEX
206-09B-2
206-09B-2
Anti-Lock Control - Stability Assist Component Location
E96714
2008.50 Kuga 8/2011
G1001224en

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206-09B-3
206-09B-3
Anti-Lock Control - Stability Assist Overview

Overview
1
8
2
3
9
E96701
Item
Description
Item
ABS/ESP module or hydraulic control unit

(HCU)
Rear wheel sensor, right-hand side
Front wheel sensor, left-hand side
Steering Wheel Rotation Sensor
Combined yaw rate sensor and lateral

acceleration sensor / longitudinal
acceleration sensor
Rear wheel sensor, left-hand side
Wiring harness
2008.50 Kuga 8/2011
Description
G1001303en

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206-09B-4
206-09B-4

Item
8
Description
Item
Front wheel sensor, right-hand side
Testing the brakes on a roller dynamometer

- 4X4 vehicles only
On 4X4 vehicles a brake test on a roller
dynamometer must only be performed under the
following conditions.
The brake test must not exceed a duration of 1
minute.
Ignition key in position 0.
The roller speed must not exceed 5 km/h.
ABS/ESP module or hydraulic control

unit (HCU)
Description
ESP switch
If accidentally dropped or knocked install a new

hydraulic control unit (HCU) and module
assembly.
When the ABS/ESP module is removed/installed
or replaced, it is necessary to reconfigure the
ABS/ESP module with the aid of the diagnostic
tester once all of the installation work has been
performed.
Refer to: Module Configuration (418-01 Module
Configuration, General Procedures).

acceleration sensor
E96821
E96822
The ABS/ESP module or the hydraulic control unit

(HCU) is mounted on the left-hand side of the
bulkhead. Diagnosis is performed with the aid of
a diagnostic tester.
The following components can be replaced
separately or as a unit:
Hydraulic Control Unit (HCU)
ABS/ESP module
Mounting Bracket
The following must be taken into account when
removing/installing or renewing the ABS/ESP
module or the hydraulic control unit (HCU):
Only hydraulic control units (HCU) which are
pre-filled with brake fluid are available for
service operations.
After replacing the HCU it is not necessary to
bleed the system via the diagnostic tester.
After replacing the brake fluid it is also only
necessary to perform standard bleeding.
The blanking caps/plugs must not be removed
until the brake tubes are ready to be connected.
2008.50 Kuga 8/2011
The sensor is attached to the floor crossmember

at the front right. For vehicles with 4x4 drive, a
longitudinal acceleration sensor is also integrated
in the same housing.
removing/installing or replacing the combined yaw
rate sensor and lateral/longitudinal acceleration
sensor:
Ensure the correct installation position of the
yaw rate sensor and lateral/longitudinal
acceleration sensor.
G1001303en

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206-09B-5
206-09B-5

Front wheel sensor
The ABS sensor rings are built into the seals in the
front wheel bearings. The wheel sensors are joined
to the main wiring harness using a separate
connecting cable.
E96823
Rear wheel sensor
E96824
4X4: The ABS sensor rings are pressed onto the

rear drive shafts. The wheel sensors are joined to
the main wiring harness using a separate
connecting cable.
Opto-electronic steering wheel rotation

sensor
4X2: The ABS sensor rings are built into the hubs
of the rear wheel bearings. When installing a
replacement bearing, ensure that the new part is
aligned correctly. The wheel sensors are joined to
the main wiring harness using a separate
connecting cable.
E80158
2008.50 Kuga 8/2011
G1001303en

TO MODEL INDEX
206-09B-6
206-09B-6

Vehicles with ESP are equipped with an
opto-electronic steering wheel rotation sensor as
an integral part of the clockspring.
removing/installing or replacing the opto-electronic
steering wheel rotation sensor:
If installing a new clockspring, remove the
clockspring locking screw.
ESP switch
E99006
Stability assist can be deactivated via the menu in

the instrument cluster.
2008.50 Kuga 8/2011
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206-09B-7
206-09B-7
Anti-Lock Control - Stability Assist System Operation and

System Diagram
7
10
10
9
M
11
11
13
13
12
18
26
25
14
15
23
24
17
16
18
22
E82694
Item
Description
18
18
21
18
20
Item
19
Description
Brake booster
Pulsation damper
Primary hydraulic circuit
engine control module
Secondary hydraulic circuit
Damping chamber
Pulsation damper
Dual circuit hydraulic pump
2008.50 Kuga 8/2011
G1001304en

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206-09B-8
206-09B-8

Item
Description
Item
Description
D.C. motor
18
Pressure sensor (5 off)
10
Solenoid-operated pilot valve (2 off)
19
LH front brake (secondary circuit)
11
Solenoid-operated priming valve (2 off)
20
RH rear brake (secondary circuit)
12
One way check valve
21
LH rear brake (primary circuit)
13
Low-pressure accumulator (2 off)
22
RH front brake (primary circuit)
14
Solenoid-operated inlet valve (RH rear

brake)
23
Solenoid-operated outlet valve (RH front

brake)
15
Solenoid-operated inlet valve (LH front

brake)
24
Solenoid-operated outlet valve (LH rear

brake)
16
Solenoid-operated outlet valve (LH front

brake)
25
Solenoid-operated inlet valve (LH rear

brake)
17
Solenoid-operated outlet valve (RH rear

brake)
26
Solenoid-operated inlet valve (RH front

brake)
System Operation
The HCU features 3 operating modes:
Normal braking: Initially, no current is supplied to
any of the solenoid-operated valves. Operating the
brake pedal produces a corresponding increase
or decrease of pressure in the brakes, through the
open pilot valves and inlet valves. If the ABS
module determines that EBD is necessary, it
energizes the inlet valves for both the rear brakes,
to isolate the brakes from any further increase in
hydraulic pressure.
ABS braking:If the ABS module determines that
ABS braking is necessary, it actuates the inlet and
outlet valves of the relevant brake and starts the
hydraulic return pump. The inlet valve closes to
isolate the brake from pressurized fluid; the outlet
valve opens to release pressure from the brake
into the accumulator and the return pump circuit.
The brake releases slightly and the wheel starts to
2008.50 Kuga 8/2011
turn again. The ABS control unit then operates the

inlet and outlet valves to regulate the hydraulic
pressure acting on the brake in order to maximize
braking effect without the wheel locking up. Control
of the valves for each wheel takes place
individually.
Active braking: With active braking, pressure is
generated for other braking functions than the
normal and ABS braking systems, e.g. for the ESP
and TCS systems. For active braking, the ABS
module energizes the pilot valves and priming
valves, starts the return pump and energizes all of
the inlet valves. Brake fluid, drawn from the
reservoir through the master cylinder and priming
valve, is pressurized by the return pump and
supplied to the inlet valves. The ABS control unit
then actuates the inlet and outlet valves in order
to regulate the pressure for the individual brakes.
Some noise may be generated during active
braking.
G1001304en

TO MODEL INDEX
206-09B-9
206-09B-9

PRINCIPLES OF OPERATION
16
4
15
8
5
14
10
11
12
13
E97570
2008.50 Kuga 8/2011
G1001304en

TO MODEL INDEX
206-09B-10
206-09B-10

Item
Description
Battery
Battery junction box (BJB) in the engine

compartment
Powertrain Control Module (PCM)
Instrument cluster
Data link connector (DLC)
Steering Wheel Rotation Sensor

(HCU)
The ABS monitors the different wheel speeds of

the vehicle with the aid of wheel speed sensors.
Using the data from all of the wheel speed sensors,
the ABS module calculates the so-called reference
speed, which is a measure of the actual road
speed. The ABS module compares the individual
circumferential wheel speeds with this reference
speed when the driver initiates braking. If one or
more of the circumferential wheel speeds deviates
too far from the reference speed, this means that
slip at the affected wheels is so great that steering
stability of the vehicle is no longer ensured. The
ABS module actuates electro-mechanical valves
which influence the brake pressure at the relevant
wheels.
Like the traction control system (TCS), the ESP
system uses a large proportion of the ABS
components. In addition, there are sensors which
pick up the steering angle, the acceleration forces
acting on the vehicle and the yaw rate or yaw
moment. The sensors transmit these signals to the
combined ABS/ESP module. Using the wheel
speed and steering angle data, the ABS/ESP
module calculates the direction of travel planned
by the driver and determines the corresponding
speed-dependent lateral acceleration and yaw
moment. These values are compared with those
actual measured. If the actual lateral acceleration
and the yaw moment deviate excessively from the
target values (unstable driving characteristics), the
ABS/ESP module actuates individual brakes
selectively via the HCU (hydraulic control unit). In
addition, the engine speed is reduced by
intervention in the engine management system.
How the system works for understeer: In the
event of understeer, brake intervention occurs at
the wheels on the inside of the curve. The rear
wheel is braked heavily, so that a high amount of
2008.50 Kuga 8/2011
Item
Description

acceleration sensor
10
Front wheel sensor
11
Rear wheel sensor
12
Rear wheel sensor
13
Front wheel sensor
14
ESP switch
15
Rear brakes
16
Front brake
slip is caused. In this way, the cornering force of

the rear axle is heavily reduced and the centrifugal
force that now becomes effective turns the rear of
the vehicle back into the curve. The front wheel is
not braked as hard. The braking force that is
transmitted via the front wheel to the road surface
generates a torque with the aid of the lever arm
(vertical tire force to the vehicle's centre of gravity),
which supports the yaw moment of the vehicle.
Both measures together result in the vehicle
reverting back to the curved path intended by the
driver.
How the system works for oversteer: In the
event of oversteer the wheels on the outside of the
curve are braked. This time, the front wheel is
subjected to a high level of slip so that the
cornering force at the front axle is reduced. The
rear wheel is not braked as heavily and, together
with the effective lever arm, results in a reduction
in the vehicle yaw moment. Both measures
together result in the vehicle being stabilized and
reverting back to the curved path intended by the
driver.
If ESP control occurs, possible ABS interventions
will be overridden as the ESP works at higher slip
rates than the ABS.
Emergency brake assist (EBA): The emergency
brake assist helps drivers in emergency braking
situations by automatically applying the brakes with
the maximum possible braking force.
If the brake pedal is pressed very suddenly, the
ABS module increases the hydraulic pressure to
all of the brakes until the threshold for ABS
intervention is reached. This applies the maximum
braking effort for the available traction. The ABS
control unit monitors inputs from the brake pedal
switch and from the pressure sensor within the
G1001304en

TO MODEL INDEX
206-09B-11
206-09B-11

HCU to check for sudden actuation of the brakes.
With the brake pedal pressed, the ABS module
triggers emergency braking if the rate of increase
of hydraulic pressure exceeds the predetermined
limit.
If the brake pedal is pressed so hard that the ABS
becomes active on the front wheels then the ABS
control unit increases the pressure to the rear
wheel brakes up to the ABS intervention threshold.
EBA operation continues until the driver releases
the brake pedal sufficiently for the hydraulic
pressure in the HCU to drop below a threshold
value stored in the ABS module.
Trailer stability control: If the vehicle is ordered
with a trailer coupling then the Trailer Stability
Control function is integrated in the ESP. The ESP
detects snaking when driving with a trailer and
reduces the speed of the vehicle and trailer through
adapted braking and, if necessary, by also reducing
the engine output until the snaking movement of
the trailer is corrected.
Roll-over protection: The ESP dynamically
determines the tipping tendency of the vehicle and
works in conjunction with the EBA system to
prevent the vehicle from tipping over during
dynamic maneuvers like lane changing or while
negotiating bends.
Emergency brake light:The emergency brake
light automatically switches on the hazard flasher
system to warn drivers of other vehicles that
emergency braking is being initiated. Based on a
defined delay value, the ABS/ESP module sends
a signal to the generic electronic module (GEM)
via the CAN data bus. The GEM activates the
hazard flasher system, that then flashes 7 times.
Prerequisites for activation of the emergency brake
light are:
The speed is higher than 50 km/h.
The brake pedal is being actuated.
The deceleration is greater than 9 m/s.
possible to draw conclusions about the absolute

tyre pressure. It is also not possible to monitor the
spare tyre pressure. In order for the system to
operate correctly, the tyre pressures must be
regularly checked and corrected and the system
subsequently initialised (see below).
The tire pressure monitoring system used here,
depending on the equipment level, is built into the
anti-lock braking system (ABS) as an extra function
and therefore does not have its own sensors.
The ABS module measures the loss of pressure
in the tyres by calculation using the wheel speed
sensors of the ABS system. If a tyre loses
pressure, its diameter decreases and the speed of
the wheel therefore increases. If the ABS module
detects such a loss in pressure, it sends a signal
to the instrument cluster via the CAN bus and a
warning message is displayed in the message
centre. The warning threshold depends among
other things on the dimension of the tyres being
used, the vehicle operating conditions and the
status at the last initialisation. Since neither the
absolute tyre pressure nor the position of the tyre
is known, the pressure of all the tyres must be
checked and the system re-initialised after a tyre
pressure warning. If necessary, the cause of the
loss of pressure must be investigated.
Regular tyre pressure checks are still necessary.
The system must be initialised after a tyre is
changed, winter or summer tyres fitted, the
pressures corrected or adjusted to suit the vehicle
load. This can be done by the driver using the
driver information system. For further information,
see: Owners Manual.
Opto-electronic steering wheel rotation
sensor
To prevent activation on snow or ice, for example,

the following prerequisites must be met:
The speed is higher than 50 km/h.
The brake pedal is being actuated.
ABS regulation takes place.
The deceleration is greater than 6 m/s.
Tire pressure monitoring system:The tire
pressure monitoring system used in the Kuga is
able to detect loss of air in a tire at an early stage
and warn the driver. Because it can only compare
the behaviour of the tyres with each other, it is not
2008.50 Kuga 8/2011
E80158
G1001304en

TO MODEL INDEX
206-09B-12
206-09B-12

The opto-electronic steering wheel rotation sensors
use light barriers for contactless scanning of a
segment disk which is connected fixedly to the
steering shaft.
specific steering angle there is therefore a specific

switch status of all photoelectric barriers.

(HCU)
1
1
2
3
E97648
Item
Description
Segment disk
Photoelectric barrier
Electronics
Electrical connection
Use is made of opto-electronic types of sensors

with relative and absolute steering angle sensing.
For relative steering angle sensing, changes in the
steering angle are measured exclusively by the
sensor and transmitted to the ABS/ESP module.
With the aid of other vehicle status signals (e.g.
wheel speed sensors) the module calculates the
straight ahead position of the steering. For absolute
steering angle sensing, the sensor transmits a
specific signal to the module for each steering
angle position (in relation to one turn of the steering
wheel). The straight ahead position of the steering
is therefore defined in the sensor. On an absolute
steering angle sensor, several photoelectric barrier
modules are distributed around the segment disk
at varying distances. The gaps between segments
of the segment disk are also unequal. For each
2008.50 Kuga 8/2011
ABS Pump Motor
Valve block (with low-pressure

accumulators)
ABS module
The HCU comprises the ABS module, the valve

block (with low-pressure accumulators) and the
ABS pump.
E54014
Item
1
2
Description
The valve block combines all of the brake pressure

control valves in one unit. Depending on the
system, either simple changeover valves or
proportioning valves (e.g. on EBD (electronic brake
force distribution) systems) are installed. The
low-pressure accumulators store the brake fluid
that is returned from the wheel brakes during the
pressure reduction phase until it is drawn back into
the system by the ABS pump.
The ABS pump is designed as a dual piston pump.
This means that two separate pump elements
assure an increase in brake pressure during control
interventions. A direct current motor drives the
pump pistons via an eccentric shaft.
The ABS/ESP module monitors the input signals
of all sensors and actuates the electro-magnetic
brake pressure valves and the ABS pump as
required. For reasons of safety, the module is of
the redundant type, whereby processing of the
signals is carried out via two separate processors
that also monitor each other.
G1001304en

TO MODEL INDEX
206-09B-13
206-09B-13

ESP switch

acceleration sensor
E99006
Stability assist can be deactivated via the menu in

the instrument cluster. The stability assist functions
are deactivated when the Set switch is actuated.
The ABS control module makes the stability assist
functions available once more when the Set switch
is actuated again. The stability assist function is
automatically reactivated when the ignition is
switched on.
The electronic EBA is a constant function and will
remain active even if the ESP has been switched
off.
2008.50 Kuga 8/2011
E96822
The heart of the combined yaw rate sensor and

lateral acceleration sensor/longitudinal acceleration
sensor is a small, double-sided tuning fork made
of a piezo crystal (A). The exciter side of this tuning
fork is set to a resonance of 11 kHz with the aid of
an alternating current. The measuring side of the
tuning fork features a resonance frequency of 11.33
kHz and therefore does not vibrate (B). Since,
under influence of an external accelerating force,
a vibrating mass reacts slower than a comparable
mass that is not vibrating, the tuning fork twists
within itself with rotational movement being
imparted on the sensor (C). This rotation results
in a change in the charge distribution in the Piezo
element, which is subsequently picked up and
converted into an electronic signal by electronics
integrated into the sensor. This electronic signal is
then sent to the ESP module. The ESP module
evaluates these data and takes into account the
other input data (vehicle speed, wheel speed)
before deciding whether the ESP function is
required.
G1001304en

TO MODEL INDEX
206-09B-14
206-09B-14
E53340
Item
Description
Tuning fork exciter
Suspension
Measuring side
Due to the special way in which it works. the

combined yaw rate sensor and lateral acceleration
sensor/longitudinal acceleration sensor must be
installed the right way up in the designated location
specified by the manufacturer. Any slight deviation
in the installation position and/or installation
location could lead to impaired functionality and
thereby possible failure of the stability assist.
Front wheel sensor
E96823
Active sensors are used to determine the rotational

speeds of the wheels at the hub. After the ignition
is switched on, the ABS module supplies the
sensors with power. The sensors work in
accordance with the Hall effect principle and
2008.50 Kuga 8/2011
G1001304en

TO MODEL INDEX
206-09B-15
206-09B-15

generate a square wave output signal. The signal
acts in proportion to the rotational speed of the
sensor ring. The ABS sensor rings are built into
the seals in the front wheel bearings. The ABS
module evaluates the signals from all four sensors
to calculate a vehicle speed signal based on the
rotational speeds of all wheels. The road speed is
transmitted on the CAN bus. The powertrain control
module (PCM) uses this signal and the

programmed tire size to calculate the vehicle
speed. The calculated vehicle speed is forwarded
on the CAN bus and is requested by other control
units that need this input information.
Rear wheel sensor
E96824
The sensors are joined to the main wiring harness

using a separate connecting cable.
2008.50 Kuga 8/2011
G1001304en

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206-09B-16
206-09B-16
Hydraulic Control Unit (HCU)

Removal

5. NOTE: Make sure that the seal is correctly
located.
Torque: 18 Nm
2. Refer to: Battery (414-01 Battery, Mounting and

3. Torque: 12 Nm
E69767

6.
E100290
4. 1. Connect one end of a suitable piece of clear

plastic pipe to the brake caliper bleed nipple
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the brake
fluid is drained from the brake fluid reservoir.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the
opposite side brake caliper.
E66148
7. Torque: 18 Nm
E86914
2008.50 Kuga 8/2011
G1001225en

TO MODEL INDEX
206-09B-17
206-09B-17
E101093
All vehicles
8. NOTE: Make sure that the seal is correctly
located.
2. Torque: 18 Nm
3. Torque: 9 Nm
2008.50 Kuga 8/2011
G1001225en

TO MODEL INDEX
206-09B-18
206-09B-18
1
2
x4
E99307
9. Torque: 9 Nm
x3

Procedures).
E69769
10. Refer to: Stability Assist Module (206-09

and Installation).
Installation
1.
CAUTION: If accidentally dropped or

knocked install a new hydraulic control
unit (HCU) and module.
The blanking caps/plugs must not be
removed until the brake tubes are ready to
be connected.
2008.50 Kuga 8/2011
G1001225en

TO MODEL INDEX
206-09B-19
206-09B-19
Stability Assist Module

General Equipment
Materials
Pneumatic Vacuum Gun
Metal Adhesive Kit - 2

Component
Name
Specification
WSK-M2G342-A /
2U7J-M2G400-AA
Removal
1. Refer to: Hydraulic Control Unit (HCU) (206-09
and Installation).
2.
E101091
3. Clean the HCU contact surface.

Material: Metal Adhesive Kit - 2 Component
(WSK-M2G342-A / 2U7J-M2G400-AA) cleaner
4. Remove all traces of the cleaner and foreign
material.
General Equipment: Pneumatic Vacuum Gun
Installation
1.
WARNING: Make sure that the module

is correctly located on the hydraulic
control unit (HCU).
CAUTION: If accidentally dropped or
knocked install a new hydraulic control
unit (HCU) and module.
Take extra care not to damage the seal.
2008.50 Kuga 8/2011
G1001226en

TO MODEL INDEX
206-09B-20
206-09B-20

NOTE: Make sure that the seal is correctly
located.
Torque: 5,5 Nm
E101092
2. Refer to: Hydraulic Control Unit (HCU) (206-09

and Installation).
3. Configure the stability assist program.
General Equipment: Ford approved diagnostic
tool
4. Carry out the stability assist program Function
Test.
tool
5. Carry out a road test.
Refer to: Road/Roller Testing (100-00 General
2008.50 Kuga 8/2011
G1001226en

TO MODEL INDEX
206-09B-21
206-09B-21
Front Wheel Speed Sensor

Removal
2. Torque: 5 Nm
E71878
Installation
2008.50 Kuga 8/2011
G1001227en

TO MODEL INDEX
206-09B-22
206-09B-22
Rear Wheel Speed Sensor

Removal
4x2
All vehicles
4. NOTE: The O-ring seal is to be reused unless
damaged.
1. Torque: 5 Nm
E98820
E98809
Installation
4x4
3. Torque: 5 Nm
1. NOTE: Make sure that the sensor housing is

clean and free of foreign material.
NOTE: Make sure that the sensor ring is
correctly located.
E98810
2008.50 Kuga 8/2011
G1001228en

TO MODEL INDEX
206-09B-23
206-09B-23
Yaw Rate Sensor

Removal
1. Refer to: Front Seat (501-10 Seating, Removal
and Installation).
Installation
2.
E99493
3.
E99496
4. Torque: 9 Nm
E99499
2008.50 Kuga 8/2011
G1058755en

TO MODEL INDEX
211-00-1
Steering System - General Information
211-00-1
SECTION 211-00 Steering System - General

Information
CONTENTS
PAGE

Steering System.................................................................................................................
Components Tests..............................................................................................................
Steering Gear Checks After a Collision..............................................................................
211-00-2
211-00-2
211-00-2
211-00-6
GENERAL PROCEDURES
Power Steering System Flushing.......................................................................................
Power Steering System Filling............................................................................................
Power Steering System Vacuum Bleeding.........................................................................
211-00-8
211-00-9
211-00-10

TO MODEL INDEX
211-00-2
211-00-2
Steering System
205-316 (15-097A)
15097

Components Tests
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073

Mechanical
Tire pressure(s)
Loose tie-rod end(s)
Loose strut and
spring assemblies or
ball joints
Loose pinch bolts on
steering column
shaft flexible coupling
Wheels and tires
Power steering line
fluid leaks
Steering gear
bellows
2008.50 Kuga 8/2011
Electrical
Battery
Battery cables
Steering angle
sensor electrical
connector
Power steering
pump control
module electrical
connectors
Power steering
pump control
module ground
cable
Power steering
pump control
module ground
cable retaining
screw
Steering angle
sensor warning
indicator
Fuse(s)
Steering Linkage
1. Grasp the steering wheel firmly and move it up
and down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead
position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
G1059437en

TO MODEL INDEX
211-00-3
211-00-3

1. Raise and support the vehicle. REFER to:
(100-02 Jacking and Lifting)
TIE0005729
TIE0005728
2. Firmly grasp the road wheel and apply a rocking

motion checking for any free play in the wheel
bearing or suspension components.
3.
CAUTION: To prevent damage to the

steering linkage, turn the steering wheel to
move the steering linkage to the right-hand
steering lock stop.
5. Detach the steering gear boot from the steering

gear body and check for free play at the tie-rod
inner ball joint.
6. If there is free play at the tie-rod inner ball joint,
install a new tie-rod.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation)
/ Tie Rod (211-03 Steering Linkage, Removal
and Installation).
7. Check the tie-rod end for free play. Install a new
tie-rod end if necessary.
Linkage, Removal and Installation)
/ Tie Rod (211-03 Steering Linkage, Removal
and Installation).
Turn the steering wheel to position the steering

linkage against the right-hand steering lock stop.
8.
CAUTION: To prevent damage to the

steering linkage, turn the steering wheel to
move the steering linkage to the left-hand
steering lock stop.
Turn the steering wheel to position the steering
linkage against the left-hand steering lock stop.
TIE0005727
4. NOTE: To isolate the steering gear design

clearance, check the right-hand steering
linkage with the steering held against the
right-hand steering lock stop.
With the aid of another technician holding the
steering linkage against the right-hand steering
lock stop, firmly grasp the road wheel and apply
a rocking motion checking for any free play in
the steering linkage.
TIE0005727
9. NOTE: To isolate the steering gear design

clearance, check the left-hand steering
linkage with the steering held against the
left-hand steering lock stop.
With the aid of another technician holding the
steering against the left-hand steering lock stop,
2008.50 Kuga 8/2011
G1059437en

TO MODEL INDEX
211-00-4
211-00-4

firmly grasp the road wheel and apply a rocking
motion checking for any free play in the steering
linkage.
5. Using a suitable torque wrench and socket,

check the steering wheel turning effort.
6. If the steering wheel turning effort is greater than
the specification, install a new steering gear.
Steering Column Universal Joint

1.
E56375
10. Detach the steering gear boot from the steering

gear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint,
install a new tie-rod.
WARNING: Install a new steering column

to steering gear pinion retaining bolt. Failure
to follow this instruction may result in
personal injury.
Detach the steering column from the steering
gear pinion.
Discard the steering column to steering gear
pinion retaining bolt.
1
REFER to: Tie Rod (211-03 Steering Linkage,

12. Check the tie-rod end for free play. Install a new
tie-rod end if necessary.

Linkage, Removal and Installation).
TIE45919
Turning Effort Test

NOTE: Before carrying out this test, make sure
that the suspension components are serviceable.
that the steering column is serviceable.
that the toe adjustment and tire pressures are
correct.
2. Check for smooth movement of the steering

column universal joint.
1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight
movement.
If the movement is not smooth or resistance
is felt, install a new steering column.
REFER to: Steering Column (211-04 Steering
1. Park the vehicle on a dry, even surface and

apply the parking brake.
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
3. Connect the air bag simulators to the
sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
2008.50 Kuga 8/2011
TIE45918
3. Hold both of the steering column universal joint

yokes and twist them clockwise and
counterclockwise.
G1059437en

TO MODEL INDEX
211-00-5
211-00-5

If movement is felt, install a new steering
column.
REFER to: Steering Column (211-04 Steering
2008.50 Kuga 8/2011
G1059437en

TO MODEL INDEX
211-00-6
211-00-6
Steering Gear Checks After a Collision

General Equipment
Feeler gauge
Straight edge
Items to be observed when checking the steering
system
The following list of steering gear conditions and

the methods of testing should be taken into account
when carrying out checks to the steering system:
If the steering gear has no faults after
completing the following checks, do not install
a new steering gear.
Surface corrosion and marks on the tie-rod are
acceptable.
When checking for turning effort torque peaks
in the steering gear, turn the steering wheel from
steering lock stop to steering lock stop in
approximately 15 seconds.
A steady increase of turning effort torque from
steering center to steering lock stop is
acceptable.
When checking for power steering fluid leaks,
turn the steering wheel to the steering lock stop
in approximately 10 seconds.
Noises from the power steering, for example
the power steering pump relief valve, are
acceptable.
STEERING GEAR HOUSING
1. Raise and support the vehicle.
2. Visually inspect the steering gear housing for
cracks and damage. If the steering gear housing
is cracked or damaged, install a new steering
gear.
REFER to: Steering Gear (211-02 Power
Steering, Removal and Installation).
TIE-RODS
1. Using a straight edge and feeler gauge, check
the tie-rods to see if they are straight. If the
distance between the tie-rod and straight edge
2008.50 Kuga 8/2011
is greater than 0.5 mm, install a new steering

gear.
2. Check the tightening torque of the tie-rod end
to wheel knuckle nut.
3. Check the tightening torque of the tie-rod end
locking nut.
CHECK FOR TURNING EFFORT TORQUE
PEAKS IN THE STEERING GEAR
1. Lower and support the vehicle making sure that
the road wheels are just clear of the floor.
2. With the ignition switch in position I, slowly turn
the steering wheel from steering lock stop to
steering lock stop. If a turning effort torque peak
or judder is felt while turning the steering wheel,
detach the tie-rods from the wheel knuckles.
3. Slowly turn the steering wheel from steering
lock stop to steering lock stop. If a turning effort
torque peak or judder is felt while turning the
steering wheel, install a new steering gear.
CHECK FOR POWER STEERING FLUID LEAKS
2. Run the engine at a fast idle and slowly turn the
steering wheel to the left-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
at the steering wheel rim.
3. Turn the steering wheel away from the left-hand
steering lock stop for 30 seconds.
4. Run the engine at a fast idle and slowly turn the
steering wheel to the right-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
at the steering wheel rim.
5. Turn the steering wheel away from the
right-hand steering lock stop.
6. Check for power steering fluid leaks at the
steering gear housing and the power steering
line connections to the steering gear. If there is
G538091en

TO MODEL INDEX
211-00-7
211-00-7

a power steering fluid leak at the steering gear,
install a new steering gear.
2008.50 Kuga 8/2011
G538091en

TO MODEL INDEX
211-00-8
211-00-8
GENERAL PROCEDURES
Power Steering System Flushing

Materials
Name
Hydraulic Fluid DP-PS
1.
Specification
WSS-M2C204-A2 /
5U7J-M2C204-AA

escaping fluids.
Using a blanking cap, cap the power steering
fluid reservoir.
E74090
2. Place the end of the steering gear return line

into a container.
3. Fill the power steering reservoir to the MAX
mark.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
4. Raise the vehicle until the road wheels are clear
of the floor. Support the vehicle.
5. NOTE: This step requires the aid of another
technician.
1. Start the engine and slowly turn the steering
from steering lock to steering lock until clean
power steering fluid comes out of the return
line.
2. With the aid of another technician, add the
power steering fluid until the system is free
of contaminated power steering fluid.
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G543411en

TO MODEL INDEX
211-00-9
211-00-9
GENERAL PROCEDURES
Power Steering System Filling

Special Tool(s)
211-189
Adapter, Power Steering
Bleeding
5. Switch the engine OFF and using the special

tools, create a vacuum of 62cm-Hg - 75cm-Hg
for 30 seconds.
Special Tool(s): 211-189, 416-D001
13016
211-189
416-D001
Hand Vacuum
Pump/Pressure Pump
416-D001
23036A
E73916
Materials
Name
Hydraulic Fluid DP-PS
Specification
WSS-M2C204-A2 /
5U7J-M2C204-AA
1. Fill the power steering fluid reservoir to the MAX

mark.
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
2. Raise the vehicle until the road wheels are clear
of the floor. Support the vehicle.
6. 1. Observe the vacuum gauge reading.

2. If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
checked for leaks.
7. Remove the special tools. Fill the power steering
fluid reservoir to the MAX mark as necessary.
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid

3. Slowly turn the steering wheel from lock to lock
and add power steering fluid until the power
steering fluid in the power steering fluid reservoir
stops dropping.
4. Start the engine and slowly turn the steering
wheel from lock to lock and add power steering
fluid until the power steering fluid in the power
steering fluid reservoir stops dropping.
2008.50 Kuga 8/2011
G543412en

TO MODEL INDEX
211-00-10
211-00-10
GENERAL PROCEDURES
Power Steering System Vacuum Bleeding

Special Tool(s)
Materials
211-189
Adapter, Power Steering
Bleeding
13016
Name
Specification
Power Steering Fluid IW WSA-M2C195-A / 9U7JM2C195-AA
Bleeding
416-D001
Hand Vacuum
Pump/Pressure Pump
9. Refer to: Steering System Health and Safety

10.
23036A
E141054
11. Material: Power Steering Fluid IW

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-11
211-00-11
GENERAL PROCEDURES
E141053
12. NOTE: Make sure the fluid in the reservoir does

not fall below the MIN mark, as air could enter
the system.
E131522

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-12
211-00-12
GENERAL PROCEDURES
E140870
14. When bleeding the power steering system the

vacuum will decrease. Using the special tools,
maintain a sufficient vacuum of 38cm-Hg. If the
211-189
vacuum decreases by more than 5cm-Hg in 5

minutes, the system should be checked for
leaks.
Install the Special Tool(s): 416-D001, 211-189
416-D001
211-189
416-D001
E140871
15. Remove the Special Tool(s): 211-189, 416-D001
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-13
211-00-13
GENERAL PROCEDURES
211-189
416-D001
211-189
416-D001
E140871

the system.
E131522

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-14
211-00-14
GENERAL PROCEDURES
E140870
18. 1. Using the special tools, create a vacuum of

38cm-Hg. Maintain the vacuum until the air
is evacuated from the system (minimum of
five minutes).
2. Release the vacuum.
211-189
416-D001
211-189
416-D001
E140871
19. Remove the Special Tool(s): 211-189, 416-D001
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-15
211-00-15
GENERAL PROCEDURES
211-189
416-D001
211-189
416-D001
E140871

the system.
E131522

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-00-16
211-00-16
GENERAL PROCEDURES
E140870
22.
E141054
2008.50 Kuga 8/2011
G1467657en

TO MODEL INDEX
211-02-1
Power Steering
211-02-1
SECTION 211-02 Power Steering

CONTENTS
PAGE

Power Steering (Component Location)..............................................................................
Power Steering (Overview).................................................................................................
Power Steering...................................................................................................................
Steering gear......................................................................................................................
Electro-hydraulic power steering pump..............................................................................
Pressure and return lines...................................................................................................
Power Steering (System Operation and Component Description).....................................
System Diagram.................................................................................................................
Electronic principle of operation......................................................................................
Hydraulic principle of operation......................................................................................
Electro-hydraulic power steering pump..........................................................................
Integrated steering angle sensor - vehicles built up to 09/2009.....................................
Brushless DC motor with integral power steering module..............................................
211-02-2
211-02-3
211-02-3
211-02-4
211-02-5
211-02-6
211-02-7
211-02-7
211-02-8
211-02-8
211-02-9
211-02-9
211-02-9
211-02-10
211-02-11

Power Steering Pressure Line and Return Line Assembly 2.5L Duratec
(147kW/200PS) - VI5....................................................................................
Power Steering Pump 2.5L Duratec (147kW/200PS) - VI5.......................
Power Steering Pump to Steering Gear Pressure Line 2.5L Duratec
(147kW/200PS) - VI5....................................................................................
Steering Gear.................................................................................................
Steering Gear to Power Steering Fluid Reservoir Return Line 2.5L Duratec
(147kW/200PS) - VI5....................................................................................
(13 443 0)
(13 434 0)
(13 440 0;
13 443 0)
(13 116 0)
211-02-13
211-02-18
211-02-21
211-02-25
(13 439 0)
211-02-36

TO MODEL INDEX
Power Steering
211-02-2
211-02-2
Power Steering Component Location
E96448
Item
Description
Integrated steering angle sensor - vehicles

built up to 09/2009
2008.50 Kuga 8/2011
G1001311en

TO MODEL INDEX
Power Steering
211-02-3
211-02-3
Power Steering Overview

Power Steering
4
1
E96186
Item
Description
Item
Description
Reservoir
Power steering fluid pressure line
Electro-hydraulic power steering pump
Heat shield
power steering return hose
Steering gear
The EHPS system uses an electrically driven

hydraulic pump and a conventional rack and pinion
steering gear. This ensures precise steering
2008.50 Kuga 8/2011
operation and steering assistance with minimum

energy consumption.
G1001269en

TO MODEL INDEX
Power Steering
211-02-4
211-02-4

Steering gear
5
4
1
6
2
1
3
E96209
Item
Description
Tie-rod end
Tie-rod
steering gear boot
The steering gear is mounted on the front axle

crossmember and is secured with two bolts. The
bolts are inserted in the steering gear from above
and screwed into the threaded lugs on the front
axle crossmember.
The following components can be renewed
separately or as a unit:
Complete steering gear
Steering gear rubber bushes
Tie rods.
Steering gear boot
Tie-rod end
Steering angle sensor - vehicles built up to
09/2009
2008.50 Kuga 8/2011
Item
Description
Steering angle sensor - vehicles built up

to 09/2009
Input shaft
Valve unit housing

components of the steering gear, pay attention to
the following: (excluding steering angle sensor)
Before undertaking repair work on an accident
damaged steering gear, the scope of the repair
must be determined using the inspection
instructions "Steering gear inspection after an
accident". For additional information, refer to
"Diagnosis and Testing" in this section.
When the steering gear is removed and
installed, the front axle crossmember must be
aligned with the bodywork using the appropriate
special tools.
G1001269en

TO MODEL INDEX
Power Steering
211-02-5
211-02-5

3
4
E96414
Item
Description
Cap, reservoir
The electro-hydraulic power steering pump is

mounted at the front right-hand side in the wheel
housing.
2008.50 Kuga 8/2011
Item
Description
Rubber bushes, electro-hydraulic power

steering pump
Bracket #1
Bracket #2

Cap, reservoir
G1001269en

TO MODEL INDEX
Power Steering
211-02-6
211-02-6

Rubber bushes, electro-hydraulic power steering
pump
Bracket #1
Bracket #2
components of the electro-hydraulic power steering
pump, pay attention to the following:
Before starting work to renew the
electro-hydraulic power steering pump, the
program code of the electro-hydraulic power
steering must be read out using the diagnostic

unit and noted.
After the work to renew the electro-hydraulic
power steering pump is completed, the
electro-hydraulic power steering must be
reconfigured using the diagnostic unit. For
further information, see: Module Configuration
(418-01 Module Configuration, General
Procedures).
The electro-hydraulic power steering pump must
be filled and vented as specified.
Pressure and return lines
1
4
E96417
Item
Description
Item
Description
power steering return hose
Bracket #1
Power steering fluid pressure line
Bracket #2
2008.50 Kuga 8/2011
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Power Steering
211-02-7
211-02-7
Power Steering System Operation and Component Description

System Diagram
2
11
12
3
1
4
10
5
9
6
8
E96391
2008.50 Kuga 8/2011
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Power Steering
211-02-8
211-02-8

Item
Description
Item

with integrated power steering module
(page 5)
Steering gear

built up to 09/2009
10)
High pressure pipe
10
Fluid Return Line
11
12
Battery
Ignition switch
Data link connector (DLC)
ABS module or ESP module
Description
System Operation
Electronic principle of operation
The power steering module requires the following
information in order to ensure precise steering
behavior in all driving situations:
The engine operating status is made available to

the power steering module as a CAN bus signal
from the PCM.
The power steering module obtains the vehicle

configuration information via the CAN bus from the
GEM. This information is required by the power
steering module in order to define the internal
characteristics of the power steering.
Steering wheel position

Rate of turn of the steering wheel
Vehicle speed
Information about the vehicle configuration
Information about the ignition switch position
Instantaneous engine operating status
The required information is made available to the

power steering module via direct connections and
via the CAN bus (refer to the flow chart).
The steering wheel position and the rate of turn of
the steering wheel are transmitted to the power
steering module as PWM signals from the steering
angle sensor. The steering angle sensor receives
its voltage and ground supply from the power
steering module and operates inductively with an
input voltage of 5 V.
The power steering module obtains information

about the current ignition switch position via the
voltage input (terminal 15) of the ignition switch.
Whilst constantly monitoring the relevant input
signals the power steering module accesses stored
maps. With the aid of this information the pump
speed is matched to the current driving situation.
An electronic diagnosis of the electro-hydraulic
power steering can be performed with the aid of a
diagnostic tester via the DLC of the vehicle. For
additional information please refer to "Diagnosis
and Testing" in this section.
The vehicle speed is made available to the power

steering module as a CAN bus signal from the ABS
module or ESP module.
2008.50 Kuga 8/2011
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Power Steering
211-02-9
211-02-9

Hydraulic principle of operation
8
7
E96442
Item
Description
Item
Description
Reservoir
Outlet of the power steering pump
Valve unit
Steering rack and pinion

5)
Flow control/pressure relief - return
Low pressure suction line
Flow control/pressure relief valve
When the engine is started, the electro-hydraulic

power steering pump sucks in power steering fluid
from the reservoir. The fluid flows through the pump
and is discharged under high pressure from the
outlet. The high-pressure line carries the power
steering fluid to the servo valve.
If no steering effort is applied, there is no resistance
to the circulation of power steering fluid and the
supply pressure from the pump is very low. Only
minimal pressure is applied by the servo valve to
the two sides of the piston in the working cylinder.
When the steering wheel is turned in either
direction, the return flow of fluid to the reservoir is
2008.50 Kuga 8/2011
restricted by the servo valve, causing the pressure

to increase on the supply side. The power steering
fluid is directed by the servo valve to the
corresponding side of the piston in the working
cylinder, providing the power assistance required
to reduce the steering effort. The power steering
fluid which is displaced towards the low-pressure
side of the cylinder flows through the servo valve
and the return line back to the reservoir.
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Power Steering
211-02-10
211-02-10
1
2
E96312
Item
Description
Reservoir
Hydraulic pump
Brushless DC motor with integral power

steering module
11)
NOTE: The power steering pump must be filled

and vented as specified.
The electro-hydraulic power steering pump
comprises a brushless DC motor, the hydraulic
pump and the power steering fluid reservoir.
The hydraulic pump is a gear pump; a resonance
chamber incorporated into the pump body reduces
noise emissions.
The operating pressure is also regulated by means
of a pressure limiting valve which is integrated in
the pump housing. The pressure limiting valve
stabilizes the throughput to the steering gear to a
particular level independently of engine speed.
The pressure relief valve will operate if the
discharge from the pump is restricted, for example,
2008.50 Kuga 8/2011
steering held on full lock. If the output from the

pump is blocked, all output is recirculated through
the pump. As no fresh fluid from the reservoir is
drawn into the pump in the process, the
temperature of the power steering fluid in the pump
quickly increases. Consequently, periods of holding
the steering wheel at full lock should be kept to a
minimum to prevent overheating of the pump and
the power steering fluid within it.
The pressure limiting valve limits the pressure on
the outlet side to 120 bar.

built up to 09/2009
G1001270en

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211-02-11
Power Steering
211-02-11
E96430
The steering angle sensor is a inductive sensor.

The steering angle sensor monitors the steering
wheel position and the rate of turn of the steering
wheel. This information is sent to the power
steering module.
On vehicles built from 09/2009 the power steering
module uses the information from the steering
2008.50 Kuga 8/2011
angle sensor at the steering column. The required

information is made available to the power steering
module via the CAN bus.
Brushless DC motor with integral power

steering module
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Power Steering
211-02-12
211-02-12

1
2
3
4
5
6
10
9
8
7
E42460
Item
Description
Item
Description
Connector
Cover
Power steering module
Rotor with magnets
Seal
Stator
Bearing
Distributor
Shaft
10
Bearing
In the electrohydraulic power steering system, a

brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
consumption in the majority of phases in a drive
cycle.
The system has a continuously variable pump

rotational speed.
Commutation in the motor is done electronically.

As a result, there are no brushes to wear away.
The entire system is designed for maintenance-free
operation.
In more than 85% of all driving situations, the
power steering pump operates at standby speed
and consumes less than 4A. However, pump speed
can quickly increase to full rotational speed if
emergency steering manoeuvres require it.
2008.50 Kuga 8/2011
G1001270en

TO MODEL INDEX
Power Steering
211-02-13
211-02-13
Power Steering Pressure Line and Return Line Assembly 2.5L

Duratec (147kW/200PS) - VI5(13 443 0)
5.
General Equipment
Removal
E99631

6.
3.
x7

escaping fluid.
1. General Equipment: Hose Clamp
Remover/Installer
2. Torque: 30 Nm
E98543
4.
E114706
7. 1. Torque: 23 Nm
2. Torque: 7 Nm
E99630
2008.50 Kuga 8/2011
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TO MODEL INDEX
Power Steering
211-02-14
211-02-14
E112634

are sealed.
Torque: 18 Nm
8. Torque: 4 Nm
E99258
9.

escaping fluid.
2008.50 Kuga 8/2011
E114705
10.
G1185534en

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211-02-15
Power Steering
211-02-15
E114708
Installation
2008.50 Kuga 8/2011
G1185534en

TO MODEL INDEX
211-02-16
Power Steering
211-02-16
x4
E114707
4.
3.
E141078
E141077

the system.
Slowly turn the steering wheel from lock to lock
five times.
2008.50 Kuga 8/2011
G1185534en

TO MODEL INDEX
Power Steering
211-02-17
211-02-17
E131522
6.
E141079
7.
E141077
2008.50 Kuga 8/2011
G1185534en

TO MODEL INDEX
Power Steering
211-02-18
211-02-18
Power Steering Pump 2.5L Duratec (147kW/200PS) VI5(13 434 0)

5.
General Equipment
Hose Clamp(s)
Removal
3.
E99631
6. 1.

escaping fluid.
General Equipment: Hose Clamp(s)

Remover/Installer
x7
E98543
4.
E114163
7. 1.

escaping fluid.
Torque: 30 Nm
Remover/Installer
4. Torque: 10 Nm
E99630
2008.50 Kuga 8/2011
G1176952en

TO MODEL INDEX
Power Steering
211-02-19
211-02-19
x3
x3
x3
x3
E112533
2.
8.
E141077
E114164
Installation
2008.50 Kuga 8/2011
G1176952en

TO MODEL INDEX
Power Steering
211-02-20
211-02-20

3.

the system.
five times.
E141078
E131522
6.
5.
E141077
E141079
2008.50 Kuga 8/2011
G1176952en

TO MODEL INDEX
Power Steering
211-02-21
211-02-21
Power Steering Pump to Steering Gear Pressure Line 2.5L

Duratec (147kW/200PS) - VI5(13 440 0; 13 443 0)
5.
General Equipment
Removal
E99631

6.
3.
x7

escaping fluid.
Remover/Installer
2. Torque: 30 Nm
E98543
4.
E114706
7. 1. Torque: 23 Nm
2. Torque: 7 Nm
E99630
2008.50 Kuga 8/2011
G1185535en

TO MODEL INDEX
Power Steering
211-02-22
211-02-22
E112634

are sealed.
Torque: 18 Nm
8. Torque: 4 Nm
E99258
9.

escaping fluid.
2008.50 Kuga 8/2011
E114705
10.
G1185535en

TO MODEL INDEX
Power Steering
211-02-23
211-02-23
E114708
11.
2
x4
x4
1
1
E114776
2008.50 Kuga 8/2011
G1185535en

TO MODEL INDEX
Power Steering
211-02-24
211-02-24

Installation
3.

2.
E141078

the system.
E141077

five times.
E131522
6.
5.
E141077
E141079
2008.50 Kuga 8/2011
G1185535en

TO MODEL INDEX
Power Steering
211-02-25
211-02-25
Steering Gear(13 116 0)

205-880
3. Torque: 30 Nm
E93105
211-020
E66155
4. On both sides.
13006

Transmission Jack
5. If equipped.
Materials
Name
Specification
Power Steering Fluid IW WSA-M2C195-A / 9U7JM2C195-AA
x7
Removal
2.

E98543
6. If equipped.
Torque: 8 Nm

E75215
7.
E99259
2008.50 Kuga 8/2011

G1001271en

TO MODEL INDEX
Power Steering
211-02-26
211-02-26

On both sides.
Torque: 48 Nm
10.
E98346
E99197
8. On both sides.
11. Torque:
Stage 1: 35 Nm
Stage 2: Loosen 360
Stage 3: 85 Nm
211-020
E99198
E89385
9.

12. Torque: 48 Nm
E98334
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
211-02-27
Power Steering
211-02-27
E99054

are sealed.
Torque: 20 Nm
13. Torque: 4 Nm
E99258
E99257
14.

escaping fluid.
2008.50 Kuga 8/2011
15.
G1001271en

TO MODEL INDEX
211-02-28
Power Steering
211-02-28
E99250

1. Torque: 70 Nm
2. Torque:
Stage 1: 140 Nm
Stage 2: 180
3. Torque: 125 Nm
E99060
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
Power Steering
211-02-29
211-02-29
1
E99100
19. Torque:
Stage 1: 40 Nm
Stage 2: 60
18.
120 mm
E99099
E99260
Installation
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
211-02-30
Power Steering
211-02-30
205-880
E99249
4.
3. Right-hand side.
E131500
E114799
5.
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
211-02-31
Power Steering
211-02-31
E131518

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
Power Steering
211-02-32
211-02-32
E131502

the system.

five times.
E131522

(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
2008.50 Kuga 8/2011
G1001271en
211-02-33

TO MODEL INDEX
Power Steering
211-02-33
E131677
10. Right-hand side.
9.
E99631
E131500
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
Power Steering
211-02-34
211-02-34

12.
11.
E141078
E141077

the system.
five times.
E131522
15.
14.
E141077
E141079
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
211-02-35
Power Steering
211-02-35

All vehicles
2008.50 Kuga 8/2011
G1001271en

TO MODEL INDEX
Power Steering
211-02-36
211-02-36
Steering Gear to Power Steering Fluid Reservoir Return Line

2.5L Duratec (147kW/200PS) - VI5(13 439 0)
5.
General Equipment
Removal
E99631

6.
3.
x7

escaping fluid.
Remover/Installer
2. Torque: 30 Nm
E98543
4.
E114706
7. 1. Torque: 23 Nm
2. Torque: 7 Nm
E99630
2008.50 Kuga 8/2011
G1185536en

TO MODEL INDEX
Power Steering
211-02-37
211-02-37
E112634

are sealed.
Torque: 18 Nm
8. Torque: 4 Nm
E99258
9.

escaping fluid.
2008.50 Kuga 8/2011
E114705
10.
G1185536en

TO MODEL INDEX
Power Steering
211-02-38
211-02-38
E114708
11.
2
x4
x4
1
1
E114777
2008.50 Kuga 8/2011
G1185536en

TO MODEL INDEX
Power Steering
211-02-39
211-02-39

Installation
3.

2.
E141078

the system.
E141077

five times.
E131522
6.
5.
E141077
E141079
2008.50 Kuga 8/2011
G1185536en

TO MODEL INDEX
211-03-1
Steering Linkage
211-03-1
SECTION 211-03 Steering Linkage

CONTENTS
PAGE

Tie Rod End.................................................................................................... (13 273 0)
Tie Rod........................................................................................................... (13 263 0)
Steering Gear Boot......................................................................................... (13 134 0)
211-03-2
211-03-3
211-03-5

TO MODEL INDEX
Steering Linkage
211-03-2
211-03-2
Tie Rod End(13 273 0)

Special Tool(s)
211-020
4. NOTE: Make sure that the tie rod end is

installed with the same number of turns as when
removed.
13006
Removal
2.
1. Torque: 69 Nm
2. Torque: 48 Nm
2
E69728
Installation
1
E69553
211-020
E69554
2008.50 Kuga 8/2011
G1001768en

TO MODEL INDEX
Steering Linkage
211-03-3
211-03-3
Tie Rod(13 263 0)

204-169
Clamping Tool, Boot
Retaining Clamp

before removal.
14044
211-245
Socket, Steering Gear
Tie-Rod
TIE0001041
13025
4.
Vise
Vise Jaw Protectors
Removal
1. Refer to: Steering Gear (211-02 Power Steering,
TIE0001042
2. NOTE: Make sure that the tie rod end is

installed with the same number of turns as when
removed.
5. General Equipment: Vise

General Equipment: Vise Jaw Protectors
Torque: 69 Nm
TIE0001043
TIE0001046
2008.50 Kuga 8/2011
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TO MODEL INDEX
Steering Linkage
211-03-4
211-03-4

Installation
Torque: 110 Nm
211-245
TIE0001044
2. NOTE: Make sure that these components are

204-169
E69906
2008.50 Kuga 8/2011
G1058710en

TO MODEL INDEX
Steering Linkage
211-03-5
211-03-5
Steering Gear Boot(13 134 0)

Special Tool(s)
204-169
Clamping Tool, Boot
Retaining Clamp

14044
Removal
1. Refer to: Tie Rod End (211-03 Steering Linkage,
2.
E99467
Installation
204-169
E69906
2008.50 Kuga 8/2011
G1001769en

TO MODEL INDEX
211-04-1
Steering Column
211-04-1
SECTION 211-04 Steering Column

CONTENTS
PAGE

Steering Column (Overview)..............................................................................................
General overview................................................................................................................
Steering wheel....................................................................................................................
Extension, steering shaft....................................................................................................
Steering Column.................................................................................................................
211-04-2
211-04-2
211-04-3
211-04-3
211-04-3

Steering Wheel............................................................................................... (13 524 0)
Steering Column............................................................................................. (13 542 0)
Steering Column Shaft........................................................................................................
211-04-4
211-04-5
211-04-7

TO MODEL INDEX
Steering Column
211-04-2
211-04-2
Steering Column Overview

General overview
1
6
3
2
E98628
Item
Description
Item
Description
Driver airbag
Steering column lower shroud
Refer to: Air Bag and Safety Belt

Pretensioner Supplemental Restraint
System (SRS) (501-20 Supplemental
Restraint System, Description and
Operation).
Steering column upper shroud
Steering Column
Steering lock
Extension, steering shaft
Steering wheel
Steering gear to bulkhead seal
Switch unit, steering column
Refer to: Steering Column Switches

(211-05 Steering Column Switches,
2008.50 Kuga 8/2011
G1030751en

TO MODEL INDEX
Steering Column
211-04-3
211-04-3

Steering wheel
Steering Column
1
2
E98657
E98646

steering wheel, pay attention to the following:
Make sure that the vehicle electrical system is
fully depowered and no other power source is
connected.
The clockspring rotor must not be turned during
removal or installation of the steering wheel.
Secure the clockspring rotor with adhesive tape
to the clockspring outer.
Make sure that the pins of the clockspring are
not bent or damaged during installation.
Item
Description
Steering Column
Bolt, steering shaft flexible coupling

Steering Column
components of the steering column, pay attention
to the following:
connected.
Make sure a new steering column flexible
coupling bolt is installed.
removal or installation of the steering wheel or
the steering column switch unit.
E98647
Item
Description
Bolt, steering shaft extension

components of the steering shaft extension, pay
attention to the following:
Make certain that a new steering shaft extension
bolt is installed.
Make sure a new steering column flexible
coupling bolt is installed.
2008.50 Kuga 8/2011
G1030751en

TO MODEL INDEX
211-04-4
Steering Column
211-04-4
Steering Wheel(13 524 0)

General Equipment
Adhesive Tape
4.

clockspring rotor does not rotate.
General Equipment: Adhesive Tape
Removal
1. Refer to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
2.

E102968
Installation
E99259
3. Torque: 48 Nm
E99634
2008.50 Kuga 8/2011
G1058717en

TO MODEL INDEX
211-04-5
Steering Column
211-04-5
Steering Column(13 542 0)

4.
Removal
WARNINGS:
components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
E95563
5.
1. NOTE: Make sure that the road wheels are in

1
2
E99639
6.
E99259
2.

Refer to: Battery Disconnect and Connect
3. If equipped.
E99720
E100834
2008.50 Kuga 8/2011
G1058718en

TO MODEL INDEX
211-04-6
Steering Column
211-04-6

7.
E101339
8. Torque: 30 Nm
E66155
9. Torque: 24 Nm
E99642
Installation
2008.50 Kuga 8/2011
G1058718en

TO MODEL INDEX
211-04-7
Steering Column
211-04-7
Steering Column Shaft

Removal
WARNINGS:
3. Torque: 5 Nm

components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
1. Refer to: Clockspring (501-20 Supplemental
Restraint System, Removal and Installation).
Refer to: Steering Column Multifunction Switch
LH (211-05 Steering Column Switches,
Refer to: Steering Column Multifunction Switch
RH (211-05 Steering Column Switches,
Refer to: Steering Column Lock Module (211-05
Steering Column Switches, Removal and
Installation).
E99641
4.
2. Torque: 30 Nm
E99640
5. Torque: 24 Nm
E66155
E99642
Installation
2008.50 Kuga 8/2011
G1073504en

TO MODEL INDEX
211-05-1
Steering Column Switches
211-05-1
SECTION 211-05 Steering Column Switches

CONTENTS
PAGE

Steering Column Switches (Component Location).............................................................
Steering Column Switches (Overview)...............................................................................
Switch unit, steering column...............................................................................................
Clockspring.........................................................................................................................
211-05-2
211-05-3
211-05-3
211-05-3

Steering Column Lock Module...........................................................................................
Steering Column Multifunction Switch LH..........................................................................
Steering Column Multifunction Switch RH..........................................................................
211-05-4
211-05-6
211-05-7

TO MODEL INDEX
211-05-2
211-05-2
Steering Column Switches Component Location
E98630
2008.50 Kuga 8/2011
G1034383en

TO MODEL INDEX
211-05-3
211-05-3
Steering Column Switches Overview

Switch unit, steering column
E98629
Item
Description
Left-hand switch, steering column
Switch unit carrier, steering column
Right-hand switch, steering column
Item
4
The clockspring is designed to carry signals

between the RCM and the driver air bag module.
The clockspring is installed on the steering column,
and consists of fixed and moving parts connected
by a coiled Mylar tape with internal conducting
tracks. The Mylar tape is able to 'wind up' and
'unwind' as the steering wheel is rotated,
maintaining electrical contact at all times between
the RCM and the driver air bag module.
2008.50 Kuga 8/2011
Steering wheel rotation sensor

Refer to: Anti-Lock Control - Stability
Assist (206-09 Anti-Lock Control Stability Assist, Description and
Operation).
Clockspring
Description
Clockspring

clockspring, pay attention to the following:
Before installation of the clockspring, it must be
aligned according to the installation instructions.
connected.
removal or installation of the steering wheel or
the steering column switch unit.
G1030755en

TO MODEL INDEX
211-05-4
211-05-4
Steering Column Lock Module

General Equipment
Removal
4.
1.
1
E99719
E99717
5.

3.
E99720
6.
E99718
x2
E99721
Installation
2008.50 Kuga 8/2011
G1058706en

TO MODEL INDEX
211-05-5
211-05-5

2. Initialize the Steering Column Lock Module.
tool
2008.50 Kuga 8/2011
G1058706en

TO MODEL INDEX
211-05-6
211-05-6
Steering Column Multifunction Switch LH

Removal
1.
E91152
2.
2
E99639
3.
E99649
Installation
2008.50 Kuga 8/2011
G1058704en

TO MODEL INDEX
211-05-7
211-05-7
Steering Column Multifunction Switch RH

Removal
1.
E91152
2.
2
E99639
3.
E99650
Installation
2008.50 Kuga 8/2011
G1058705en
BACK TO MAIN INDEX

TO MODEL INDEX
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TO MODEL INDEX
303-00-1
Engine System - General Information
303-00-1
SECTION 303-00 Engine System - General Information

CONTENTS
PAGE

Engine.................................................................................................................................
Engine - Oil Leaks..............................................................................................................
Ultraviolet (UV) Testing.......................................................................................................
Measure the compression pressure...................................................................................
Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5))..............................
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel).............
Measure the oil pressure (21 113 0)...................................................................................
Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5))...............................................
Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)..............................
Valve train analysis - static (engine off)..............................................................................
303-00-2
303-00-9
303-00-9
303-00-9
303-00-10
303-00-11
303-00-14
303-00-14
303-00-16
303-00-17

TO MODEL INDEX
303-00-2
303-00-2
Engine
system

Socket, Spark Plug
303-499
ES21202
Compression Test Adapter

303-1056
Coolant leaks
Oil leaks
Fuel system leaks
Visibly damaged or
worn parts
Loose or missing
nuts or bolts
E42936

Materials
Name
Adhesive - Loctite 243
Symptom
Loss of oil

Mechanical
Electrical
Fuse(s)
Loose or corroded
connector(s)
Control module
Damaged or worn
switch(es)
Specification
WSK-M2G349-A7
Possible Sources
Action
Oil leaks on components that CHECK for evidence of oil

are either coated in oil themleaks on components. Use an
selves or on components local
ultraviolet (UV) leak tester if an
to them.
oil leak is not evident. INSTALL
new gaskets or components as
required.
Internal or external leak at the CHECK the coolant expansion
oil cooler.
tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
Oil consumption
2008.50 Kuga 8/2011
Leak at the crankshaft seal.
INSTALL a new crankshaft

seal.
Leaks from oil carrying

components or basic engine.
CHECK for cracks in oilcarrying components of the

basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
Use of the wrong type of engine DETERMINE the last type of

oil.
engine oil used and compare
with the specification. Change
the engine oil to the specification.
G1055128en

TO MODEL INDEX
303-00-3
303-00-3

Symptom
Possible Sources
Action
Faulty positive crankcase vent- CHECK if the PCV system is

ilation (PCV) system.
operating correctly and repair
- Hoses or ventilation or
as necessary. Engine - 2.5L
breather valves are blocked.
Duratec-ST (VI5) This causes excessive
REFER to: Engine Emission
pressure in the crankcase
Control (303-08 Engine
which causes more oil to
Emission Control - 2.5L
enter the combustion
Duratec (147kW/200PS) chamber.
VI5, Diagnosis and Testing).
- PCV oil separator is faulty
Engine - 2.0L Duratorq-TDCi
and engine oil can enter the
(DW) Diesel combustion chamber
through the intake manifold.
Turbocharger seals.
INSTALL a new turbocharger.

Engine - 2.5L Duratec-ST (VI5)
REFER to: Turbocharger (30304 Fuel Charging and
Controls - Turbocharger 2.5L Duratec (147kW/200PS)
- VI5, Removal and Installation).
(DW) Diesel -
Damaged gaskets or mating

surfaces.
- Cylinder head gasket is
damaged or mating face are
warped.
- Valve stem seals are worn
and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.
CHECK the gaskets and mating

surfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine block
mating faces.
INSTALL new valve seals. Engine
- 2.5L Duratec-ST (VI5) -
Piston ring or cylinder liner

wear.

necessary.
REFER to: Valve Stem Seals

(303-01 Engine - 2.5L Duratec
(147kW/200PS) - VI5, Removal
and Installation).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
Damaged cylinder liners or

CHECK the running surfaces
excessive clearance of engine
and clearances of the individual
components.
engine components. INSTALL
- Pistons.
new components as necessary.
- Piston rings (clearance in
INSTALL a new cylinder block
groove and end gap).
if necessary.
- Cylinder liners.
Check the pistons and piston
rings.
2008.50 Kuga 8/2011
G1055128en

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303-00-4
303-00-4

Symptom
Coolant consumption
Possible Sources
Cooling system components.
Action
Check the cooling system
components. Engine - 2.5L
Duratec-ST (VI5) REFER to: Engine Cooling
(303-03 Engine Cooling,
(DW) Diesel REFER to: Engine Cooling
Oil cooler.
INSTALL a new oil cooler.
Damaged gaskets or warped

mating faces.
CHECK the cylinder head

gasket for damage. CHECK the
cylinder head for distortion.
Cracks or fractures in engine DETERMINE the damaged

components surrounded by
engine component(s) and
coolant, such as cylinder liners
install new component(s) as
and cylinder head combustion
necessary.
chamber.
Engine will not crank
Battery or cables.
CHECK the battery and cables.

REFER to: Charging System
(414-00 Charging System General Information,
Starter motor or cables.
CHECK the starting system.

REFER to: Starting System
(303-06 Starting System 2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
(DW) Diesel -
Engine cranks but will not start Fuel tank is empty.
2008.50 Kuga 8/2011
CHECK the fuel level.
Water in fuel (diesel engine

only).
Drain the water from the fuel

system.
Fuel filter blocked.
INSTALL a new fuel filter.

(DW) Diesel -
G1055128en

TO MODEL INDEX
303-00-5
303-00-5

Symptom
Possible Sources
Engine intake air system.
Action
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
(DW) Diesel -
Glow plug faulty (diesel engine CHECK the glow plugs.

only).
INSTALL new glow plugs as
necessary.
Engine management system.
CHECK the engine management system. Engine - 2.5L

Duratec-ST (VI5) REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) VI5, Diagnosis and Testing).
(DW) Diesel -
Ignition system (petrol engine CHECK the ignition system.

only).
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Incorrect valve timing.
CHECK and adjust the valve

timing. Engine - 2.5L DuratecST (VI5) REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
(DW) Diesel -
2008.50 Kuga 8/2011
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TO MODEL INDEX
303-00-6
303-00-6

Symptom
Possible Sources
Broken or damaged timing
belt/timing chain or
pulley/sprocket.
Action
CHECK the timing belt/timing
chain and sprockets/pulleys.
necessary. Engine - 2.5L
Duratec-ST (VI5) REFER to: Timing Belt (303-01
(147kW/200PS) - VI5,
(DW) Diesel -
Very poor power output or fuel Fuel system.

consumption too high or engine
running rough.
CHECK the fuel system.

REFER to: Fuel Charging and
Controls (303-04 Fuel Charging and Controls - 2.5L
(DW) Diesel -
Engine intake air system.
CHECK the intake air system.

REFER to: Intake Air Distribution and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
(DW) Diesel -
Exhaust system blocked.
CHECK the exhaust system.
Engine management system.
CHECK the engine management system. Engine - 2.5L

Duratec-ST (VI5) REFER to: Electronic Engine
(DW) Diesel -
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-7
303-00-7

Symptom
Possible Sources
Action
Fault in ignition system (petrol CHECK the ignition system.

engine only).
Turbocharger.
CHECK the turbocharger.

(DW) Diesel -
Incorrect valve timing. Timing

belt/timing sprocket or
pulley/sprocket damaged.
CHECK and adjust valve

timing. INSTALL new components as necessary. Engine 2.5L Duratec-ST (VI5) REFER to: Timing Belt (303-01
(147kW/200PS) - VI5,
(DW) Diesel -
Ignition timing incorrect (petrol CHECK the electronic engine

engine only).
controls. Engine - 2.5L DuratecST (VI5) REFER to: Electronic Engine
Noisy running
Engine auxiliary components

loose or damaged.
CHECK engine auxiliary

components for damage or
looseness. CHECK and adjust
valve timing. INSTALL new
REFER to: Timing Belt (303-01
(147kW/200PS) - VI5,
(DW) Diesel -
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-8
303-00-8

Symptom
Possible Sources
Noisy running, misfiring, back- Incorrect fuel

firing or knocking
Action
DETERMINE which type of fuel
was last put into the fuel tank
(note the country specific fuel
specifications).
Water in fuel or fuel contamin- CHECK the fuel system for

ated.
water or other contamination.
Valve timing incorrect, timing
belt/chain or pulley/sprocket
damaged.
CHECK and adjust valve

timing. INSTALL new components as necessary. Engine 2.5L Duratec-ST (VI5) REFER to: Timing Belt (303-01
(147kW/200PS) - VI5,
(DW) Diesel -
Noisy running or valve train

noise
Valve clearance too large due INSTALL new hydraulic lash

to faulty valve tappets or worn
adjusters or adjust the valve
valve train components.
clearance. Engine - 2.5L
Duratec-ST (VI5) REFER to: Valve Clearance
Adjustment (303-01 Engine 2.5L Duratec (147kW/200PS)
- VI5, General Procedures).
(DW) Diesel Timing belt or timing chain
damaged.
INSTALL a new timing belt or

timing chain. Engine - 2.5L
Duratec-ST (VI5) REFER to: Timing Belt (303-01
(147kW/200PS) - VI5,
(DW) Diesel -
Timing belt or timing chain

incorrectly tensioned.
CHECK the timing belt tension.

INSTALL a new timing belt or
timing chain as necessary.
(147kW/200PS) - VI5,
(DW) Diesel -
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-9
303-00-9

Symptom
Possible Sources
Noisy running or engine noise Engine components

- Pistons.
- Piston rings.
- Connecting rod big end,
main bearing or thrust
bearing journals.
- Connecting rods bent or
damaged.
Engine - Oil Leaks

NOTE: Before installing new gaskets or oil seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing

1. Clean the engine and transmission with a
suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
Action
CHECK the engine components for wear or damage. Make
sure that all components are
within specification. INSTALL
new components as necessary.
REFER to: Specifications (30301 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Specifications).
(DW) Diesel -
disconnected. This error message must be deleted

from the fault memory using the Ford diagnostic
equipment after completing the compression test.
NOTE: Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
WARNING: Vehicles with manual transaxle,

shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five
minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
5. Check the engine for oil leaks using a suitable
UV lamp.
6. Rectify any leaks found and check the engine
for oil leaks.
Measure the compression pressure

NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-10
303-00-10

(Engine - 2.5L Duratec-ST (VI5))
5. Connect the battery ground cable.

REFER to: Battery Disconnect and Connect
x5
E68679
6. Using Special Tool 303-499, remove the spark

plugs.
TIE44608
1. Remove the central junction box (CJB) cover.

E68434
NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with
the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
TIE44609
28 Nm
2. Open the CJB and remove the fuel pump relay.

3. NOTE: The engine will start, run for a few
seconds and then stop.
Start the engine.
4. Remove the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
E68680
8. Using Special Tool 303-499, install the spark

plugs.
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-11
303-00-11

9. Install the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
TIE44609
10. Install the fuel pump relay and close the CJB.
or near any fuel related components.

Highly flammable vapors are always
present and can ignite. Failure to follow
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below 30C,
whichever is the greater. Failure to follow
injury.
1. Using datalogger in the Ford diagnostic
equipment, check that the fuel pressure has
dropped to zero and that the fuel temperature
has either reached ambient temperature or is
below 30C, whichever is the greater.
VFE0035742
3. Remove the engine undershield.
TIE44608
11. Install the CJB cover.

(Engine - 2.0L Duratorq-TDCi (DW)
Diesel)
VFE0035752
4. Remove the radiator undershield.
WARNINGS:
Do not smoke or carry lighted tobacco or
open flame of any type when working on
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-12
303-00-12

Failure to follow this instruction may cause
the engine upper cover to be damaged.
NOTE: Only remove and install the engine upper
cover in the sequence shown.
Remove the engine upper cover.
Detach the engine upper cover ball clips in
the sequence shown.
TIE44583
5. Remove the glow plug relay.

7. Remove the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
TIE39594
10.
CAUTION: Do not disconnect the fuel

injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical

connectors.
11. Remove the exhaust gas recirculation (EGR)
cooler.
12. Remove the EGR valve.
E50527
8. NOTE: The engine upper cover is held in

place by 3 ball clips. The ball clips are not
vertical, but are angled backwards by
approximately 20 degrees.
Location of the engine upper cover ball clips.
1
3
TIE39687
13. Remove the glow plug power supply.

2
4
E50472
9.
CAUTION: Contact of the engine upper

cover with the cowl panel may cause damage
(scratches) on the engine upper cover. If the
ambient temperature is below 0C, detach
the engine upper cover with extreme caution.
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-13
303-00-13
3 Nm
3 Nm
TIE39592
TIE39688
14. Remove the glow plugs.
19. Install the glow plug power supply.

20. Install the EGR valve.
21. Install the EGR cooler.
303-1056
E39706
15. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the pointer on the compression tester stops
rising.
16. Carry out the measurement on all cylinders,
following the measuring equipment
manufacturer's instructions.
17. Detach the compression tester and the special
tool.
5 Nm
TIE39594
22. Connect the fuel injector electrical connectors.

23. Apply soap solution to the ball clip mountings
in the engine upper cover.
Soap solution (maximum concentration of
soap in water 1:200).
5 Nm
E50473
24.
TIE39593
18. Install the glow plugs.
2008.50 Kuga 8/2011
CAUTION: Contact of the engine upper

cover with the cowl panel may cause
damage (scratches) on the engine upper
cover. Failure to follow this instruction may
cause the engine upper cover to be
damaged.
G1055128en

TO MODEL INDEX
303-00-14
303-00-14

Put the engine cover into installation position
and clip it in place by pressing at the places
shown.
Make sure that the engine upper cover is
fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
29. Install the engine undershield.

31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)

The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L

Duratec-ST (VI5))
TIE44583
27. Install the glow plug relay.

E65955
2. Remove the engine undershield.
VFE0035752
28. Install the radiator undershield.

E68443
3. Disconnect the oil pressure switch electrical

connector.
VFE0035742
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-15
303-00-15

Measure the oil pressure.
E68435
4. Remove the oil pressure switch.
E68436
9. Detach the oil pressure gauge and connector

from the oil pressure switch bore.
10. Coat the oil pressure switch with adhesive.
E68436
5. Attach the oil pressure gauge with the oil

pressure gauge connector to the oil pressure
switch bore, and position it to allow reading from
above.
E68435
11. Install the oil pressure switch.
E68436
7. NOTE: Measure the oil pressure at an oil

temperature of 100C.
NOTE: Measure the oil pressure at idle speed and
at 4000 rpm.
E68443
12. Connect the oil pressure switch electrical

connector to the oil pressure switch.
NOTE: Minimum oil pressure at idle speed: 1.0

bar.
NOTE: Minimum oil pressure at 4000 rpm: 3.5 bar.
NOTE: Maximum oil pressure: 4.8 bar.
2008.50 Kuga 8/2011
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TO MODEL INDEX
303-00-16
303-00-16
E65955
TIE39596
13. Install the engine undershield.

4. Remove the oil pressure switch.
Measure the oil pressure (Engine - 2.0L

Duratorq-TDCi (DW) Diesel)
TIE39705
5. Attach the oil pressure gauge with the oil

pressure gauge connector.
6. NOTE: Measure the oil pressure at the
specified engine speed. Measure the oil
pressure at an oil temperature of 80 C.
NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
TIE40578
2. Remove the engine under shield.
NOTE: Oil pressure at 2000 rpm: 2.0 bar.

NOTE: Oil pressure at 4000 rpm: 4.0 bar.
Check the oil pressure.
TIE39595
3. Disconnect the oil pressure switch electrical

connector.
TIE39705
7. Detach the oil pressure gauge and the oil

pressure gauge connector.
8. Coat the oil pressure switch with adhesive.
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-00-17
303-00-17
35 Nm
TIE39704
9. Install the oil pressure switch.
TIE39595
10. Connect the oil pressure switch electrical

connector.
VFE0035742
11. Install the engine under shield.

Valve train analysis - static (engine off)

Remove the valve cover.
Check all valve train components for damage and
wear. Make sure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
2008.50 Kuga 8/2011
G1055128en

TO MODEL INDEX
303-01-1
Engine 2.5L Duratec (147kW/200PS) - VI5
303-01-1
SECTION 303-01 Engine 2.5L Duratec (147kW/200PS) - VI5

CONTENTS
PAGE
PAGE 1 OF 2
SPECIFICATIONS
Specifications......................................................................................................................
Engine Data....................................................................................................................
Engine Oil.......................................................................................................................
Engine Oil Capacity........................................................................................................
Oil Pressure....................................................................................................................
Valve Clearance..............................................................................................................
Crankshaft Main Bearing Selection................................................................................
303-01-3
303-01-3
303-01-3
303-01-3
303-01-3
303-01-4
303-01-4

Engine (Component Location)............................................................................................
Engine (Overview)..............................................................................................................
General...............................................................................................................................
Cylinder head.....................................................................................................................
Cylinder block.....................................................................................................................
Engine (System Operation and Component Description)...................................................
Variable camshaft timing.................................................................................................
303-01-6
303-01-9
303-01-9
303-01-10
303-01-14
303-01-16
303-01-16
303-01-17
GENERAL PROCEDURES
Valve Clearance Adjustment...............................................................................................
303-01-19

Intake Manifold...............................................................................................
Crankshaft Front Seal.....................................................................................
Valve Stem Seals...........................................................................................
Timing Belt......................................................................................................
Camshafts......................................................................................................
Camshaft Seal................................................................................................
Oil Pan............................................................................................................
Oil Pump.........................................................................................................
Exhaust Manifold............................................................................................
Cylinder Head.................................................................................................
Crankshaft Rear Seal.....................................................................................
Oil Cooler........................................................................................................
(21 183 0)
(21 467 0)
(21 238 0)
(21 304 0)
(21 284 0)
(21 288 0)
(21 154 0)
(21 714 0)
(21 187 0)
(21 163 0)
(21 468 4)
(21 764 0)
303-01-20
303-01-22
303-01-23
303-01-25
303-01-31
303-01-36
303-01-45
303-01-48
303-01-49
303-01-50
303-01-56
303-01-58
Engine Vehicles With: 5-Speed Automatic Transaxle (AW55)................... (21 132 0;

21 132 6;
21 132 7)
Engine Accessories........................................................................................ (21 139 4)
303-01-59
303-01-78
REMOVAL
303-01-2

TO MODEL INDEX
303-01-2
.
PAGE 2 OF 2
DISASSEMBLY
Engine............................................................................................................ (21 134 8)
303-01-84
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head................................................................................................. (21 165 6)
303-01-93
ASSEMBLY
Engine............................................................................................................ (21 134 8)
303-01-94
INSTALLATION
Engine Accessories........................................................................................ (21 139 4)
Engine Vehicles With: 5-Speed Automatic Transaxle (AW55)................... (21 132 0;
21 132 6;
21 132 7)
303-01-112
303-01-119

TO MODEL INDEX
303-01-3
303-01-3
SPECIFICATIONS
Engine Data
Description
Engine code
Firing order
HYDB
HYDC
Stage IV
Stage V
1-2-4-5-3
Emission level
Bore
83 mm
Stroke
93.2 mm
Cubic capacity
2522 cm
Compression ratio
9:1
Power output at 6000 rpm 147 kW (200 PS)

Maximum torque at 1600
rpm
320 Nm
Maximum engine speed

(intermittent)
6850 rpm
Maximum engine speed

(continous)
6500 rpm
Idle speed
770 rpm
Number of main bearings
Camshaft drive
Belt
Oil consumption
0.5 l/1000 Km
Engine Oil
Viscosity / ambient temperature
Type
Specification
Ford Formula E
WSS-M2C913-C
Ford Formula XR+
ACEA A3/B3
Ford Formula S
ACEA A3/B3
Recommended engine oil

SAE 5W-30 / below -20C to over
+40C
Alternative engine oils (for topup only)
SAE 10W-40 / -20C to over
+40C
SAE 5W-40 / below -20C to over
+40C
Engine Oil Capacity
Description
Liters
Service fill including filter
5.8
Service fill excluding filter
5.5
Oil Pressure
Description
Bar
Minimum oil pressure at 800 - 850 rpm (normal operating temperature)
1.0
Minimum oil pressure at 4000 rpm (normal operating temperature)
3.5
2008.50 Kuga 8/2011
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TO MODEL INDEX
303-01-4
303-01-4
SPECIFICATIONS
Description
Bar
Oil pressure relief valve opening pressure
4.8
Valve Clearance
Description
mm
Valve clearance (engine cold), intake
0.17 - 0.23
Valve clearance (engine cold), exhaust
0.36 - 0.43
Valves
Description
mm
Intake valve lenght
101.93 - 102.07
Intake valve shaft diameter
5.87 - 6.01
Intake valve guide clearance
0.05 - 0.07
Exhaust valve lenght
101.43 - 101.57
Exhaust valve shaft diameter
5.87 - 6.01
Exhaust valve guide clearance
0.05 - 0.07
Valve Seats
Description
degree
Intake valve seat angle
45.33 - 45.67
Exhaust valve seat angle
45.33 - 45.67
Cylinder Head
Description
mm
Cylinder head height
149.25 - 149.55
Maximum mating face distortion (lengthwise)
0.05
Maximum mating face distortion (crosswise)
0.02
Maximum face milling
0.30
Camshafts
Description
mm
Intake camshaft lobe lift
8.68
Exhaust camshaft lobe lift
9.05
Crankshaft
Description
mm
Crankshaft axial clearance
0.08 - 0.19
Crankshaft Main Bearing Selection

Code - Cylinder block
A
Crankshaft
main bearing
for:
Cylinder
block
2008.50 Kuga 8/2011
Crankshaft
main bearing
carrier
Cylinder
block
Crankshaft
main bearing
carrier
Cylinder
block
Crankshaft
main bearing
carrier
G1079019en

TO MODEL INDEX
303-01-5
303-01-5
SPECIFICATIONS
yellow
medium
yellow
medium
yellow
medium
blue thick
blue thick
blue thick
red thin
yellow
medium
yellow
medium
yellow
medium
yellow
medium
blue thick
red thin
red thin
red thin
yellow
medium
yellow
medium
yellow
medium
Code Crankshaft
2008.50 Kuga 8/2011
G1079019en

TO MODEL INDEX
303-01-6
303-01-6
Engine Component Location

Engine
1
2
4
3
6
7
8
13
12
9
11
10
E62441
Item
Description
Front engine cover
Rear engine cover
CMP (camshaft position) Sensor - intake

camshaft
CMP Sensor - exhaust camshaft
2008.50 Kuga 8/2011
Item
Description
Intake variable camshaft timing oil control

solenoid
Exhaust variable camshaft timing oil

control solenoid
Exhaust VCT control unit
Intake VCT control unit
G1032415en

TO MODEL INDEX
303-01-7
303-01-7

Item
Description
Item
Description
Timing belt idler pulley
12
Coolant pump pulley
10
Crankshaft timing belt pulley
13
Timing belt
11
Timing belt tensioner
Cylinder block
E64016
2008.50 Kuga 8/2011
G1032415en

TO MODEL INDEX
303-01-8
303-01-8

Item
Description
Cylinder block
Bedplate
2008.50 Kuga 8/2011
Item
3
Description
Oil sump
G1032415en

TO MODEL INDEX
303-01-9
303-01-9
Engine Overview
General
E62439
The 2.5L Duratec (VI5) engine is a turbo engine

with 5 cylinders and 20 valves, with electronically
controlled camshaft adjustment for both camshafts.
2008.50 Kuga 8/2011
The valve train is driven by a timing belt.
G1092773en

TO MODEL INDEX
303-01-10
303-01-10
E62614
Item
Description
Engine speed curve
Power output curve
By the use of VCT for the intake and exhaust

camshafts it is possible to attain maximum torque
across a wide engine speed range.
Cylinder head
The cylinder head consists of two parts. The top
half of the cylinder head consists of a valve cover
with integral camshaft bearing caps.
2008.50 Kuga 8/2011
G1092773en

TO MODEL INDEX
303-01-11
303-01-11
6
3
4
E62857
Item
Description
Item
Description
Camshaft bearings
Spark plug well sealing ring
Valve cover
Exhaust camshaft
Cylinder head
intake camshaft
A conventional cylinder head gasket is installed

between the cylinder head and the cylinder block.
2008.50 Kuga 8/2011
The gaskets between the other mating faces are

fluid gaskets.
G1092773en

TO MODEL INDEX
303-01-12
303-01-12

Camshafts
6
5
7
E62570
2008.50 Kuga 8/2011
G1092773en

TO MODEL INDEX
303-01-13
303-01-13

Item
Description
Item
Description
Exhaust camshaft
Intake camshaft reference mark
intake camshaft
Exhaust camshaft reference mark
Valve cover
CMP Sensor - exhaust camshaft
CMP Sensor - intake camshaft

CAUTION: Before removal, mark the
camshafts as the intake and exhaust
camshafts can be mixed up.
A reference mark for the CMP sensor is machined

into each camshaft. When the camshafts are set
precisely to the timing marks, the machined mark
on the exhaust camshaft is located roughly at the
5 o'clock position and the machined mark on the
intake camshaft is located at 8 o'clock.
When changing the toothed belts it is not necessary
to dismantle the camshaft adjustment units. A
special tool prevents the VCT control units from
turning during the adjustment process by locking
the two VCT control units to one another.
A further special tool is needed to fix the camshafts
in the adjustment position. The special tool
engages in corresponding recesses for the
reference marks on the CMP sensors.
2008.50 Kuga 8/2011
Each camshaft is fixed in place using four bearing

caps and the bearing cap VVT. The bearing caps
must not be changed around and must always be
fitted in their original positions.
The VCT control units for the intake and exhaust
camshafts are moved into the locked base position
when the engine is stopped through the
engagement of a spring-loaded locking pin. The
movement to the locked base position is assisted
by the tensile force of the timing belt for the intake
VCT control unit. With the exhaust VCT control
unit, a spring inside the control unit additionally
assists in reaching the locked base position. The
intake VCT control unit is in the "retarded timing"
position and the exhaust VCT control unit is in the
"advanced timing" position when in the locked base
position. The lock is hydraulically released when
the engine is started depending on the oil pressure.
The mechanical valve tappets are maintenance
free.
G1092773en

TO MODEL INDEX
303-01-14
303-01-14

Timing marks
E62440
Item
Description
Item
Description
Exhaust camshaft pulley timing mark
Exhaust camshaft drive gear
Engine front cover with timing marks
Crankshaft timing belt pulley timing mark
Intake camshaft pulley timing mark
Crankshaft timing belt pulley
Intake camshaft drive gear
Crankshaft
The front engine cover must always be fitted when

checking and adjusting the valve timing or timing
belt tension, as the timing marks for both camshaft
pulleys are provided on its front end.
Correct timing belt tension is ensured by the
automatic timing belt tensioner.
No direction of movement is specified when using
a new timing belt. If, however, the old timing belt
is reused, the direction of movement must be
marked prior to removal.
Once the timing belt has been correctly tensioned,
the engine must be rotated by hand two turns
clockwise at the crankshaft in order to allow a
2008.50 Kuga 8/2011
subsequent check of the timing belt tension and

adjustment.
Cylinder block
The cylinder block consists of three parts. These
are the cylinder block, the lower crankcase and the
sump pan. The cylinder block has five cylinder
liners made of cast iron, which cannot be replaced.
The pistons are made of a homogeneous aluminum
alloy with a graphite coating on the sides. This
coating serves to reduce friction and dampen noise.
The pistons are cooled from below via oil-spray
nozzles screwed into the cylinder block.
G1092773en

TO MODEL INDEX
303-01-15
303-01-15

Crankshaft
E62853
Item
Description
Item
Description
Crankshaft
Timing belt pulley splines
Timing belt pulley
Wide spline
Dowel
Crankshaft outer splines
Crankshaft inner splines
Located on the drive side of the crankshaft are two

sets of splines. The inner splines drive the oil
pump. The outer splines engage in the timing belt
pulley. The timing belt pulley can only be fitted onto
2008.50 Kuga 8/2011
the outer splines in a particular position. For this

purpose, one spline on the timing belt pulley and
one on the crankshaft have been made wider. The
dowel fixes the vibration damper in place.
G1092773en

TO MODEL INDEX
303-01-16
303-01-16
Engine System Operation and Component Description

System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52
crank angle on the intake side and 47 crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaft
2008.50 Kuga 8/2011
adjuster on the exhaust side has a torsion spring

which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
G1032416en

TO MODEL INDEX
303-01-17
303-01-17

Variable camshaft timing
Timing retard
E62711
Item
Description
Item
Description
Camshaft pulley
Return spring
Locking pin
Camshaft adjuster solenoid
Valve rotor
Duct connected to chamber (a)
Rotor vane
Duct connected to chamber (b)
Plunger
Oil feed duct
Drive Oil return duct
2008.50 Kuga 8/2011
G1032416en

TO MODEL INDEX
303-01-18
303-01-18

The engine oil is drawn from the oil pan and routed
to the camshaft oil ducts via the engine oil circuit
before passing from there to the VCT oil control
solenoid and to the locking pin. This releases the
locking pin and separates the positive engagement
between the camshaft pulley and the rotor. When
the control unit is being retarded, the chamber (b)

fills with engine oil. The rotor turns clockwise
because of the oil pressure in the chamber (b). The
engine oil returning from the chamber (a) flows via
the oil return duct (D) to the VCT oil control
solenoid and from there back into the oil pan.
E62710
When the VCT control unit is being advanced, the

chamber (a) fills with engine oil. The rotor turns
counter-clockwise because of the oil pressure in
the chamber (a). This completes the advance
adjustment. The engine oil returning from the
chamber (b) flows via the oil return duct (D) to the
VCT oil control solenoid and from there back into
the oil pan.
2008.50 Kuga 8/2011
G1032416en

TO MODEL INDEX
303-01-19
303-01-19
GENERAL PROCEDURES
Valve Clearance Adjustment

Special Tool(s)
303-1183
Holder, Camshaft
4. Measure the valve clearance and if neccessary,

adjust by installing new tappets.
Torque: 12 Nm
303-1183
E62756
1. Remove the camshafts.

Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2.
CAUTION: Make sure that the valve

tappets are installed in their original
locations.
x5
E66325
5. Repeat the measuring procedures for all

cylinders on the intake and on the exhaust side.
x20
E68493
3. Install only one pair of tappets and the camshaft

for the first measurement.
Torque: 17 Nm
303-1183
E68822
2008.50 Kuga 8/2011
G543487en

TO MODEL INDEX
303-01-20
303-01-20
Intake Manifold(21 183 0)

6.
Removal
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
3. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
E67375
7.
4.
E68413
8. Torque: 10 Nm
E65070
5.
CAUTION: Make sure that the inside of

the pipe ends are clean and free of oil
residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
3
1
E67741
2
E68504
2008.50 Kuga 8/2011
G1079020en

TO MODEL INDEX
303-01-21
303-01-21

9.
12. Torque: 10 Nm
E67742
10.
E67906
13.
E67743
11.
E64165
14. Torque: 19 Nm
E67907
E67382
Installation
2008.50 Kuga 8/2011
G1079020en

TO MODEL INDEX
303-01-22
303-01-22
Crankshaft Front Seal(21 467 0)

Special Tool(s)
211-014
Remover, Steering Wheel
13019
303-293
303-1180
Installer, Crankshaft Front
Seal
E65179
Installation
E62050

303-293
303-1180
21143
Removal
1. Refer to: Timing Belt (303-01 Engine - 2.5L
Installation).
E64880
2. NOTE: The crankshaft timing pulley can only

be installed in 1 position on the crankshaft
splines.
211-014
E64877
E64881

Installation).
2008.50 Kuga 8/2011
G543324en

TO MODEL INDEX
303-01-23
303-01-23
Valve Stem Seals(21 238 0)

Special Tool(s)
303-361B
Compressor, Valve Spring
2.
E62757
303-361B-06
Adapter for 303-361B
E66111
E62041
3. Using the special tool, apply 7 to 10 bar of

compressed air into the cylinder.
303-363
Adapter, Air Supply (Cylinder
Head)

303-363
21157
303-508
Pliers, Valve Stem Seal
E66112
21211
4. Special Tool(s): 303-361B, 303-361B-06

303-361B
Removal
1. Remove the camshafts.
303-361B-06
Refer to: Camshafts (303-01 Engine - 2.5L

Installation).
E66326
2008.50 Kuga 8/2011
G543490en

TO MODEL INDEX
303-01-24
303-01-24

303-508
E66114
Installation
1. To install reverse the removal procedure.
2008.50 Kuga 8/2011
G543490en

TO MODEL INDEX
303-01-25
303-01-25
Timing Belt(21 304 0)

303-1054
Locking Tool, Timing Belt
Tensioner
3. General Equipment: Trolley Jack
3031054
303-1179
Holding Wrench, Crankshaft
E66944
E62035
4.
2
Trolley Jack
Two Leg Puller
Removal
1. Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
Installation).
2.
1
E68472
5.
E68741
E68742
2008.50 Kuga 8/2011
G543492en

TO MODEL INDEX
303-01-26
303-01-26

6.
8.

x4
E122374
7. General Equipment: Two Leg Puller
E113365
E122375
2008.50 Kuga 8/2011
G543492en

TO MODEL INDEX
303-01-27
303-01-27

Vehicles with mechanical timing belt tensioner
9.
11.
WARNING: Take extra care when

handling the compressed spring.
2
2
3
3
303-1054
E68488
E113800
Vehicles with automatic timing belt tensioner

10.

2
303-1054
E113799
2008.50 Kuga 8/2011
G543492en

TO MODEL INDEX
303-01-28
303-01-28

Installation

installed.

installed.
1. Torque: 25 Nm
Torque: 25 Nm
1. Torque: 25 Nm
3. Torque: 25 Nm
2
3
303-1054
3
-20 C
20 C
50 C
E113801
E68489
3.

303-1054
E113802
2008.50 Kuga 8/2011
G543492en

TO MODEL INDEX
303-01-29
303-01-29

All vehicles
6. 1. NOTE: Only tighten the bolts finger tight at

this stage.
4.

2. Torque: 180 Nm
x4
x2
303-1179
1
E112858
5.

E122486
8. Torque:
Stage 1: 25 Nm
Stage 2: 60
x4
E122520
9. Torque: 10 Nm
E113365
2008.50 Kuga 8/2011
E68742
G543492en

TO MODEL INDEX
303-01-30
303-01-30

10. 1. Torque: 115 Nm
2. Torque: 90 Nm
1
2
E68740
11.
E68741

Installation).
2008.50 Kuga 8/2011
G543492en

TO MODEL INDEX
303-01-31
303-01-31
Camshafts(21 284 0)
303-1178
Timing Tool Camshaft
E62051
Punch
303-1178
Materials
Name
Engine Oil - 5W-30
Specification
WSS-M2C913-C
E66324
4. General Equipment: Punch
Flange Sealant - Anaer- WSK-M2G348-A7 /

obic LP
5U7J-M2G348-BA
Removal
1. Refer to: Camshaft Seal (303-01 Engine - 2.5L
Installation).
2.
E68948
5. Loosen each bolt 2 turns at a time until all bolts

are removed.
E113641
2008.50 Kuga 8/2011
G543491en

TO MODEL INDEX
303-01-32
303-01-32
20
13
14
21
15
22
10
16
34
28
29
30
23
43
35
44
36
37
41
42
46
45
38
19
27
33
40
32
26
39
31
25
24
12
18
17
11
E68743
2008.50 Kuga 8/2011
G543491en

TO MODEL INDEX
303-01-33
303-01-33
Installation
1. Refer to: Valve Clearance Adjustment (303-01
Engine - 2.5L Duratec (147kW/200PS) - VI5,
2. X = 15 mm.
3. Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C)
engine oil
E113630
4. Material: Flange Sealant - Anaerobic LP

(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E68818
E68870
5. Tighten each bolt 2 turns at a time.

Torque: 17 Nm
2008.50 Kuga 8/2011
G543491en

TO MODEL INDEX
303-01-34
303-01-34
46
38
27
34
45
33
26
44
32
25
43
37
31
13
19
18
17
24
12
11
10
28
20
14
15
21
16
22
23
35
29
39
40
30
41
36
42
E87508
2008.50 Kuga 8/2011
G543491en

TO MODEL INDEX
303-01-35
303-01-35

Torque: 10 Nm
x2
303-1178
3
1
303-1178
E113631
7.
E113641
8. Refer to: Camshaft Seal (303-01 Engine - 2.5L

Installation).
2008.50 Kuga 8/2011
G543491en

TO MODEL INDEX
303-01-36
303-01-36
Camshaft Seal(21 288 0)

Special Tool(s)
303-1054
Tensioner
3031054
303-1178
Removal
1. Refer to: Ignition Coil-On-Plug (303-07
Engine Ignition - 2.5L Duratec
Installation).
2. Refer to: Starter Motor (303-06 Starting
System - 2.5L Duratec (147kW/200PS) VI5, Removal and Installation).
2.
E62051
303-1179
E62035
E67902
303-1182
Timing Tool, Crankshaft
3.
E62027
x5
303-318
Aligner/Installer, Crankshaft
Front Seal
E68679
21148
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-37
303-01-37

4.

Installation).
Torque: 10 Nm
E67905
303-1178
5.
E66324
9.
E68491
6.
E68749
10.
x2
E68745
E74333
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-38
303-01-38

11.
3.
E83911
E71704
4. Using the special tool, align the crankshaft.
Installation
303-1182
303-318
E66328
E68747
2. NOTE: Only tighten the bolts finger tight at this

stage.
x2
E74333
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-39
303-01-39

5.


installed.
1. Torque: 25 Nm
3. NOTE: The timing belt tensioner setting is
dependant on the engine temperature.
Torque: 25 Nm
2
3
E113883
-20 C
20 C
50 C
E68489
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-40
303-01-40

All vehicles

installed.
9. Torque: 120 Nm
1. Torque: 25 Nm
Torque: 25 Nm
E68746

2
303-1054
303-1178
3
E66324

E113801
8.

303-1182
303-1054
E66328
E113802
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-41
303-01-41

12.
15.

x2
1
E112858
13. Using the special tool, align the crankshaft.

303-1182
E113365
16. Torque: 35 Nm
E66328

Torque: 10 Nm
E68749
303-1178
E66324
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-42
303-01-42

20. Torque: 40 Nm
303-1182
E66328
E83911
21. 1. NOTE: Make sure that new components are

installed.
2. Torque: 40 Nm
x2
303-1178
E66324
19. Torque: 17 Nm
x2
E113556
22. Torque: 10 Nm
E68745
E67905
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-43
303-01-43

27. 1. Torque: 115 Nm
2. Torque: 90 Nm
23. Torque: 28 Nm
1
x5
E68679
2
E68740
24.
28.
E67902
E68741
25. Refer to: Ignition Coil-On-Plug (303-07 Engine

26. Torque: 10 Nm

this stage.
2. Torque: 180 Nm
E68742
x4
303-1179
E122486
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-44
303-01-44

31. Torque:
Stage 1: 25 Nm
Stage 2: 60
x4
E122520
32. Install the following items:

Belt (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal
and Installation).
2. Refer to: Starter Motor (303-06 Starting
System - 2.5L Duratec (147kW/200PS) VI5, Removal and Installation).
2008.50 Kuga 8/2011
G1166799en

TO MODEL INDEX
303-01-45
303-01-45
Oil Pan(21 154 0)

General Equipment
Cable Ties
Removal
Materials
NOTE: Removal steps in the procedure may

Name
Engine Oil - 5W-30
Specification
WSS-M2C913-C

obic LP
5U7J-M2G348-BA
1. Refer to: Accessory Drive Belt (303-05

Accessory Drive - 2.5L Duratec
Installation).
Torque: 25 Nm
x3
E138810
3.
2008.50 Kuga 8/2011
G543325en

TO MODEL INDEX
303-01-46
303-01-46

escaping fluid.
Torque: 38 Nm
6. Torque: 48 Nm
E65219
E65223
7. Torque: 10 Nm
4. Torque: 17 Nm
E65220
E65764
8. Torque: 17 Nm
5. Torque: 48 Nm
x4
E65221
E65218
2008.50 Kuga 8/2011
G543325en

TO MODEL INDEX
303-01-47
303-01-47

9. Torque: 17 Nm
Installation
1. NOTE: The component must be installed within
5 minutes of applying the sealant.
Material: Flange Sealant - Anaerobic LP
(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E65222
E84444

3.
CAUTION: The fluid level must remain

between the MAX and MIN marks.
engine oil
2008.50 Kuga 8/2011
G543325en

TO MODEL INDEX
303-01-48
303-01-48
Oil Pump(21 714 0)

Special Tool(s)
211-014
4. Refer to: Crankshaft Front Seal (303-01 Engine

- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation).
Installation
13019
Removal
Installation).
211-014
E64877
3. Torque: 6 Nm
E64878
2008.50 Kuga 8/2011
G543327en

TO MODEL INDEX
303-01-49
303-01-49
Exhaust Manifold(21 187 0)

Removal
1. Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
Installation).
Installation
1. Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
Installation).
2008.50 Kuga 8/2011
G1079021en

TO MODEL INDEX
303-01-50
303-01-50
Cylinder Head(21 163 0)

6. Torque: 24 Nm
General Equipment
Fluid Container
Tire Lever
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C913-C
Grease KS-PS
SA-M1C9107-A / YS5JM1C9107-AA
Removal
E68748
7. 1. Torque: 48 Nm
2. Torque: 80 Nm
1. Refer to: Cooling System Draining and Vacuum

Procedures).
2
1

Installation).
E65766
8.

General Equipment: Tire Lever
Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA) grease
Torque: 50 Nm
x2
5.
E98184
E66052
2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-51
303-01-51

9. Torque: 24 Nm
11. Torque: 24 Nm
E112607
12.
CAUTION: Make sure that the gaskets

are correctly located.
Torque: 24 Nm
E112254
10.

residue.
E112806
13.
E66726
E65070
2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-52
303-01-52

14.
17.
E106249

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
18. Torque: 10 Nm
x8
15.
E68413
3
1
E113004
19.
2
E68504
16.

residue.
E67743
E67375
2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-53
303-01-53

20.
23. Torque: 19 Nm
E67907
21. Torque: 10 Nm
E67906
22.
E67382
24.
E68474
25. Refer to: Camshafts (303-01 Engine - 2.5L

Installation).
26. Torque: 25 Nm
E64165
E68998
2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-54
303-01-54

27.
CAUTION: Note the position of the

components before removal.
30. Torque: 25 Nm
x5
x20
E115891
E68493
31.
28.
CAUTION: Make sure that no fluids are

present in the threaded bores.
Torque:
Stage 1: 20 Nm
Stage 2: 60 Nm
Stage 3: 130
1
12
E116077
Installation
2
10
11
E68494
29.

escaping fluid.
Torque: 38 Nm
E115890
2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-55
303-01-55

2.
CAUTION: Make sure that fluid level is

to the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
engine oil
E116204

2008.50 Kuga 8/2011
G1079022en

TO MODEL INDEX
303-01-56
303-01-56
Crankshaft Rear Seal(21 468 4)

Special Tool(s)
303-1181
Installer, Crankshaft Rear
Seal
E62048

2. Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
All vehicles
303-254
Locking Tool, Flywheel
21135
303-293
E64889
21143
Removal
303-293
1.
E64890
2008.50 Kuga 8/2011
G1268481en

TO MODEL INDEX
303-01-57
303-01-57

Installation
NOTE: Make sure that the locating pin on the

crankshaft is aligned with the guide hole in the
flywheel or flexplate.

Torque:
Stage 1: 45 Nm
Stage 2: 50
303-1181
10
E64891
7
4
2
2. CAUTIONS:
E124911
Make sure that new bolts are installed.

Make sure that no excess sealant
residue is evident.

Removal).

Torque:
Stage 1: 45 Nm
Stage 2: 65
10
5
6
7
4
2
E124911
3.

4. CAUTIONS:
residue is evident.
2008.50 Kuga 8/2011
G1268481en

TO MODEL INDEX
303-01-58
303-01-58
Oil Cooler(21 764 0)

General Equipment
Fluid Container

escaping fluids.
1. General Equipment: Fluid Container
General Equipment: Hose Clamp(s)
2. Torque: 3 Nm
3. Torque: 17 Nm
Hose Clamp(s)
Materials
Name
Engine Oil - 5W-30
Specification
WSS-M2C913-C
Removal
NOTE: Removal steps in the procedure may

x2
x4
1.
E74103
Installation
E65299

2.
2.
escaping fluid.
Torque: 38 Nm
CAUTION: Make sure that fluid level is

to the MAX mark.
engine oil

Procedures).
E92766
3.
2008.50 Kuga 8/2011
G834604en

TO MODEL INDEX
303-01-59
303-01-59
REMOVAL
Engine Vehicles With: 5-Speed Automatic Transaxle

(AW55)(21 132 0; 21 132 6; 21 132 7)
Removal
303-122
Lifting Bracket, Engine

Retaining Strap
Trolley Jack
Wooden Block
21068A

Cable Ties
Hydraulic Jib Crane

Mounting Table Set
4.
E114689
5. On both sides.
Loosen: 3 turn(s)
x3
E99147
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-60
303-01-60
REMOVAL
6.
8.
E101006
7.
E112446
9.
E79327
E112311
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-61
303-01-61
REMOVAL
10.
13.
CAUTION: Make sure that no

components catch.
General Equipment: Retaining Strap
General Equipment: Trolley Jack
E112389
11.
15 mm
E106249
E112303
12.
E63329
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-62
303-01-62
REMOVAL
Vehicles with PCM security shield
16.
14.
x4
E65856
All vehicles
17.
1
2
E92343
E63326
Vehicles without PCM security shield

15.
18.

components catch.
Remove the following items:
stage.
E93509
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-63
303-01-63
REMOVAL
20.
E65070
21.
2
2
1
E116626
E116646
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-64
303-01-64
REMOVAL
30 mm
30 mm
E112390
24.
23.
E112335
E112607
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-65
303-01-65
REMOVAL
28.

Procedures).
27.
E112511
E98184
29. On both sides.
30mm
E99722
30.
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-66
303-01-66
REMOVAL
E99948

Remover/Installer
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-67
303-01-67
REMOVAL
1
2
E112764
33.
32.
E99980
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-68
303-01-68
REMOVAL
2
E112655
34.

components catch.
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-69
303-01-69
REMOVAL
1
2
E112439
36.

E98634
x3
E114754
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-70
303-01-70
REMOVAL
37.
40.
E68429
E65220
38.

Remover/Installer
E67408
E112312
39.

escaping fluid.
42.
Refer to: Quick Release Coupling (310-00 Fuel

Procedures).
E66479
E68475
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-71
303-01-71
REMOVAL
Remover/Installer
45.
x2
E68473
44.
CAUTION: Gearshift cables must not be

kinked or bent.
E114606
46.
E114728
E114436
47.
E114609
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-72
303-01-72
REMOVAL
48.
51.
2
1
x2
1
E114610
49.
E64738
52.
x6
E114611
50.
E114614
53.

are sealed.
E114612
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-73
303-01-73
REMOVAL
54.
56.

E66050
x2
55.
E112253
E112254

1. Refer to: Transfer Case (307-07 Transfer
Case - Vehicles With: 5-Speed Automatic
Transaxle - AW55 AWD/6-Speed Automatic
Transaxle - 6DCT450, Removal).
2. Refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
Installation).
58.
x2
E114619
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-74
303-01-74
REMOVAL
59.

escaping fluid.
3.

Remover/Installer
x3
x3
x3
x3
E112533
61.
60.

escaping fluid.
General Equipment: Cable Ties
1
2
E112534
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-75
303-01-75
REMOVAL
E112535
63.
WARNING: Make sure that the engine

and transmission assembly is on
wooden blocks and secured with
suitable retaining straps.
General Equipment: Mounting Table Set
General Equipment: Wooden Block
E112536
2008.50 Kuga 8/2011
G1191240en
303-01-76

TO MODEL INDEX
303-01-76
REMOVAL
E105371
64.
x4
E114696
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-77
303-01-77
REMOVAL
65.
69.
E84187

General Equipment: Hydraulic Jib Crane
E114607
66.
303-122
1
E68472
67.

components catch.
E84188

68.
E65770
2008.50 Kuga 8/2011
G1191240en

TO MODEL INDEX
303-01-78
303-01-78
REMOVAL
Engine Accessories(21 139 4)

Removal
Special Tool(s)
1.
303-122
21068A
303-254
E74122
2.
21135
303-435
Mounting Stand
1
2
21187
303-435-06
Mounting Bracket for 303-435
E63590
3.
21031B
303-435-14B
Mounting Plate for
303-435-06
E62805
E67378
2008.50 Kuga 8/2011
G1079024en

TO MODEL INDEX
303-01-79
303-01-79
REMOVAL
4.
7.
x5
E68413
5.
E115172
E67890
8. Install the Special Tool(s): 303-435, 303-435-06,

303-435-14B
6.
303-435-14B
x3
x3
303-435-06
x4
E67893
2008.50 Kuga 8/2011
E67897
303-435
G1079024en

TO MODEL INDEX
303-01-80
303-01-80
REMOVAL
12.
303-122
E67741
13.
E84188
10.
E67742
14.
E67898
11.
E67901
E67899
2008.50 Kuga 8/2011
G1079024en

TO MODEL INDEX
303-01-81
303-01-81
REMOVAL
15.
18.
E67907
E67743
16.
E67904
17.
E67903
2008.50 Kuga 8/2011
19.
E67905
20.
E67906
G1079024en

TO MODEL INDEX
303-01-82
303-01-82
REMOVAL
21.
24.
x2
E66829
E67382
22.
25.
x12
E66826
E66830
23.
26.
1
2
E66827
2008.50 Kuga 8/2011
E67909
G1079024en

TO MODEL INDEX
303-01-83
303-01-83
REMOVAL
27.
30.
E68412
E68415
E64889
29.
x4
E84148
2008.50 Kuga 8/2011
G1079024en

TO MODEL INDEX
303-01-84
303-01-84
DISASSEMBLY
Engine(21 134 8)
Disassembly
211-014
3. General Equipment: Two Leg Puller
13019
303-1054
Tensioner
3031054
E122375
Punch
Two Leg Puller
1.
4.
2
E68416
2.
3
x4
E122374
2008.50 Kuga 8/2011
E68488
G543498en

TO MODEL INDEX
303-01-85
303-01-85
DISASSEMBLY
All vehicles
5.
7.

E68408
303-1054
8.
E113799
6.

2
2
1
3
303-1054
E68490
E113800
2008.50 Kuga 8/2011
G543498en

TO MODEL INDEX
303-01-86
303-01-86
DISASSEMBLY
9.
12.
E68749
E65076
10.
13.
x2
E68491
E74333
14.
x7
211-014
E69625
2008.50 Kuga 8/2011
E68745
G543498en

TO MODEL INDEX
303-01-87
303-01-87
DISASSEMBLY
16.
E68948
20
13
14
21
15
22
10
16
34
28
29
30
23
43
35
44
36
37
41
42
46
45
19
27
33
40
32
26
39
31
25
38
24
12
18
17
11
E68743
17.
E113630
2008.50 Kuga 8/2011
18.
E68492
G543498en

TO MODEL INDEX
303-01-88
303-01-88
DISASSEMBLY
19.
22.
x20
x4
E84406
E84582
20.
23.
1
12
10
11
3
E84206
21.
E64878
24.
E68495
25.
2008.50 Kuga 8/2011

G543498en

TO MODEL INDEX
303-01-89
303-01-89
DISASSEMBLY
x10
E122192
26.

27.

x5
E122197
E77266
28.
2008.50 Kuga 8/2011
G543498en

TO MODEL INDEX
303-01-90
303-01-90
DISASSEMBLY
x5
x12
x12
E122198
29.

2008.50 Kuga 8/2011
G543498en

TO MODEL INDEX
303-01-91
303-01-91
DISASSEMBLY
x5
E122294
31.
30.

E122227
2008.50 Kuga 8/2011
G543498en

TO MODEL INDEX
303-01-92
303-01-92
DISASSEMBLY
x5
E122293
2008.50 Kuga 8/2011
G543498en

TO MODEL INDEX
303-01-93
303-01-93
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head(21 165 6)

Special Tool(s)
303-361B
Compressor, Valve Spring
303-508
E62757
303-361B-06
Adapter for 303-361B
E66114
Assembly
E62041
3. To install, reverse the assembly procedure.

303-508
Pliers, Valve Stem Seal
21211
Disassembly
1. Special Tool(s): 303-361B, 303-361B-06
303-361B
303-361B-06
E66326
2008.50 Kuga 8/2011
G543499en

TO MODEL INDEX
303-01-94
303-01-94
ASSEMBLY
Engine(21 134 8)
Assembly
303-1054
Tensioner

303-1181
Installer, Crankshaft Rear
Seal
E62048
3031054
303-1182
Timing Tool, Crankshaft
303-1178
E62027
E62051
303-318
Aligner/Installer, Crankshaft
Front Seal
303-1179
21148
E62035
Piston Ring Compressor

303-1180
Installer, Crankshaft Front
Seal

Materials
Name
E62050
Engine Oil - 5W-30
Specification
WSS-M2C913-C

obic LP
5U7J-M2G348-BA
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-95
303-01-95
ASSEMBLY
2
1
E122606
2.

components are installed to the position
noted before removal.
2008.50 Kuga 8/2011
Apply a thin coating.

engine oil
G543500en

TO MODEL INDEX
303-01-96
303-01-96
ASSEMBLY
x5
E122293
3.

2008.50 Kuga 8/2011

engine oil
G543500en

TO MODEL INDEX
303-01-97
303-01-97
ASSEMBLY
x5
E122294

4.

(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E122227
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-98
303-01-98
ASSEMBLY
E122323
6.
CAUTION: Make sure that new bolts are

installed.
Torque:
Stage 1: M10: 1-12 20 Nm
Stage 2: M10: 1-12 45 Nm
7. Torque:
M8: 13-24 24 Nm
8. Torque:
M7: 25-29 17 Nm
9. Torque:
M10: 1-12 90
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-99
303-01-99
ASSEMBLY
24
20
13
28
23
16
26
22
18
25
27
29
12
10
11
17
15
14
19
21
E122331

2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-100
303-01-100
ASSEMBLY
3
2
5
4
E122634
11.


engine oil
General Equipment: Piston Ring Compressor

x5
E122334
E77266
13. CAUTIONS:
12.

Make sure that the components are

installed to the position noted before
removal.
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-101
303-01-101
ASSEMBLY
engine oil
Torque:
Stage 1: 30 Nm
Stage 2: 90
x10
E122335
14. Torque: 10 Nm

(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E68495
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-102
303-01-102
ASSEMBLY
E84444

stage.
18. Torque: 17 Nm
E84443
E84443
19. Torque: 17 Nm
x4
E84582
E84445
2008.50 Kuga 8/2011
G543500en
303-01-103

TO MODEL INDEX
303-01-103
ASSEMBLY
20. Torque: 6 Nm
23. Torque:
Stage 1: 20 Nm
Stage 2: 60 Nm
Stage 3: 130
12
11
10
E64878
E68750
303-1180
24. X = 15 mm.
E64880

303-1181
E64891
E68818
2008.50 Kuga 8/2011
G543500en
303-01-104

TO MODEL INDEX
303-01-104
ASSEMBLY
25.
27. Apply a thin coating.

engine oil
x20
E84406
E113630
26.
28. Material: Flange Sealant - Anaerobic LP
(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E68492
E68870
29. Torque: 17 Nm
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-105
303-01-105
ASSEMBLY
46
38
27
34
45
33
26
44
32
25
43
37
31
13
19
18
17
24
12
11
10
28
20
14
15
21
16
22
23
35
29
39
40
30
41
36
42
E87508
31. NOTE: The crankshaft timing pulley can only

be installed in 1 position on the crankshaft
splines.
Torque: 17 Nm
x7
303-318
E68747
E69623
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-106
303-01-106
ASSEMBLY
stage.

final tightening.
1. Torque:
Stage 1: 35 Nm
Stage 2: 75
2. Torque:
Stage 1: 15 Nm
Stage 2: 90
x2
1
E74333
2. Torque: 12 Nm
E68408

Torque: 10 Nm
x2
303-1178
2
1
3
1
E68490
303-1178
E113631
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-107
303-01-107
ASSEMBLY
36.
38.

E83911
37.
CAUTION: Only rotate the crankshaft

clockwise.
Rotate the crankshaft slowly until the crankshaft
stops.
303-1182
E113883
E66328
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-108
303-01-108
ASSEMBLY

installed.

installed.
1. Torque: 25 Nm
3. Torque: 25 Nm
1. Torque: 25 Nm
Torque: 25 Nm
1
2
303-1054
-20 C
20 C
50 C
3
E68489
E113801
41.

303-1054
E113802
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-109
303-01-109
ASSEMBLY
All vehicles
45.
42. Torque: 120 Nm
x2
x2
E84550
1
E112858
46.

clockwise.
stops.
303-1178
E66324
44.
303-1182

clockwise.
stops.
E66328
303-1182

Torque: 10 Nm
E66328
303-1178
E66324
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-110
303-01-110
ASSEMBLY
48.

303-1182
303-1178
E113365
49. Torque: 35 Nm
E68745
E68749
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-111
303-01-111
ASSEMBLY
53. Torque: 40 Nm
56. Torque: 10 Nm
E83911
E68416
54. 1. NOTE: Make sure that new components are

installed.

this stage.
2. Torque: 180 Nm
2. Torque: 40 Nm
x2
1
2
x4
x2
E113556
55. Torque: 10 Nm
303-1179
E122486
59. Torque:
Stage 1: 25 Nm
Stage 2: 60
x4
E65076
E122520
2008.50 Kuga 8/2011
G543500en

TO MODEL INDEX
303-01-112
303-01-112
INSTALLATION
Engine Accessories(21 139 4)

Installation
Special Tool(s)
1. Torque: 17 Nm
303-122
21068A
303-254
E68407
2. Torque: 48 Nm
21135
303-435
Mounting Stand
x4
21187
303-435-06
Mounting Bracket for 303-435
21031B
E84148
303-435-14B
Mounting Plate for
303-435-06

3. CAUTIONS:
E62805
2008.50 Kuga 8/2011

residue is evident.
G1079026en

TO MODEL INDEX
303-01-113
303-01-113
INSTALLATION
All vehicles
5. Torque: 17 Nm

Torque:
Stage 1: 45 Nm
Stage 2: 65
10
5
6
7
4
E68412
6.
2
E124911

4. CAUTIONS:
residue is evident.
E67909
7. Torque: 24 Nm

Torque:
Stage 1: 45 Nm
Stage 2: 50
x12
10
5
E66830
7
4
2
E124911
2008.50 Kuga 8/2011
G1079026en

TO MODEL INDEX
303-01-114
303-01-114
INSTALLATION
8. Torque: 12 Nm
11. Torque: 19 Nm
x2
E66829
E67382
9. 1. Torque: 26 Nm
2. Torque: 38 Nm
12. Torque: 10 Nm
E67906
E66827
13. Torque: 10 Nm
10. Torque: 38 Nm
E67905
E66826
2008.50 Kuga 8/2011
G1079026en

TO MODEL INDEX
303-01-115
303-01-115
INSTALLATION
17.
14.
E67907
15.
E67903
16. Torque: 10 Nm
E67904
2008.50 Kuga 8/2011
E67743
18.
E67901
19.
E67742
G1079026en
303-01-116

TO MODEL INDEX
303-01-116
INSTALLATION
20. Torque: 10 Nm
303-122
E67741
21.
E84188
24. Remove the Special Tool(s): 303-435,

303-435-06, 303-435-14B
303-435-14B
E67899
x3
22.
303-435-06
E67897
303-435
E67898
2008.50 Kuga 8/2011
G1079026en

TO MODEL INDEX
303-01-117
303-01-117
INSTALLATION
27. Torque: 20 Nm
25. Torque: 24 Nm
x5
E67890
28.
E115172
E68413
2. Torque: 16 Nm
3. Torque: 24 Nm
29.
1
3
2
E67378
E67894
2008.50 Kuga 8/2011
G1079026en

TO MODEL INDEX
303-01-118
303-01-118
INSTALLATION
2. Torque: 15 Nm
2
1
E84101
31. Torque: 10 Nm
E74122
2008.50 Kuga 8/2011
G1079026en

TO MODEL INDEX
303-01-119
303-01-119
INSTALLATION
Engine Vehicles With: 5-Speed Automatic Transaxle

(AW55)(21 132 0; 21 132 6; 21 132 7)
Installation
303-122
21068A

Hydraulic Jib Crane
Mounting Table Set
Retaining Strap
Trolley Jack
Wooden Block
General Equipment: Hydraulic Jib Crane
14
E114801
303-122
3. Torque: 48 Nm
E84188
2008.50 Kuga 8/2011
E84187
G1191241en

TO MODEL INDEX
303-01-120
303-01-120
INSTALLATION
4. Torque: 48 Nm

final tightening.
Torque: 60 Nm
4
1
2
E65770
x6
E124910
6.
WARNING: Make sure that the engine

and transmission assembly is on
wooden blocks and secured with
suitable retaining straps.
General Equipment: Mounting Table Set
General Equipment: Wooden Block
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-121
303-01-121
INSTALLATION
E105371
7.

components catch.
Lower the vehicle.
2. Torque: 10 Nm
8.
E114729
E114607
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-122
303-01-122
INSTALLATION
10. NOTE: Only tighten the nuts and bolts finger
tight at this stage.

12. Torque: 25 Nm
1
E68472
E112536
2. Torque: 7 Nm
E112535
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-123
303-01-123
INSTALLATION
14.
Remover/Installer
4. Torque: 30 Nm
2
1
E112635
x3
x3
x3
x3
E112636
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-124
303-01-124
INSTALLATION
1. Refer to: Transfer Case (307-07 Transfer
Case - Vehicles With: 5-Speed Automatic
Transaxle - AW55 AWD/6-Speed Automatic
Transaxle - 6DCT450, Removal).
2. Refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
Installation).
17.
18. Torque: 24 Nm

Torque: 48 Nm
E112254
x2
19.
E112253
2008.50 Kuga 8/2011
E66050
G1191241en

TO MODEL INDEX
303-01-125
303-01-125
INSTALLATION
20. Torque: 6 Nm
2. Torque: 80 Nm
2
E114624
E114913
21. Torque: 50 Nm
24. Torque: 10 Nm
x2
22.

Torque: 28 Nm
E114612
25.
x3
E114611
E114754
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-126
303-01-126
INSTALLATION
29. Torque: 25 Nm
2. Torque: 9 Nm
2
1
x2
1
E114610
27. Torque: 25 Nm
E114606
30.
E114609

kinked or bent.
Refer to: Selector Lever Cable Adjustment Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD (307-05 Automatic
Transmission/Transaxle External Controls Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, General Procedures).
28.
E114728
E114436
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-127
303-01-127
INSTALLATION
Remover/Installer
32.
E66479
E68473
2. Torque: 25 Nm
3. Torque: 10 Nm
2
1
x4
E114615
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-128
303-01-128
INSTALLATION
34.
37. Torque: 10 Nm
E68429
E65220

Procedures).
38. Torque: 20 Nm
2
E68475
36. Torque: 12 Nm
Torque: 24 Nm
E112607
39. NOTE: The gasket is to be reused unless

damaged.
1
E116433
E99980
40.
2008.50 Kuga 8/2011
G1191241en
303-01-129

TO MODEL INDEX
303-01-129
INSTALLATION
E112656
2. Torque: 5 Nm
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-130
303-01-130
INSTALLATION
2
1
E112637

Remover/Installer
2008.50 Kuga 8/2011
G1191241en
303-01-131

TO MODEL INDEX
303-01-131
INSTALLATION
E112652
43. Torque: 5 Nm
E99948
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-132
303-01-132
INSTALLATION
44.
46.
E112511
45.
E65955
47.
E112335
E65929
48.
2008.50 Kuga 8/2011
G1191241en
303-01-133

TO MODEL INDEX
303-01-133
INSTALLATION
E112639
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-134
303-01-134
INSTALLATION
49.

components catch.

51.
E112653
52. Torque: 7 Nm
15 mm
E112303
E93509
50.
E112649
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-135
303-01-135
INSTALLATION

53. Torque: 7 Nm
x4
E116626
E92343
All vehicles
54.

components catch.
stage.
56.

residue.
1. Torque: 4 Nm
2. Torque: 10 Nm
2
2
1
E116646
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-136
303-01-136
INSTALLATION
57.
60.
E65070
58.
E112311
61. 1. Torque: 115 Nm

2. Torque: 90 Nm
1
E106249
2
E68740
59.
Remover/Installer
E112389
E112638
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-137
303-01-137
INSTALLATION
63. Torque: 10 Nm
64. Torque: 12 Nm
E101006
65. On both sides.

Torque: 35 Nm
x3
E112446
E99147
66.
E114689
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-01-138
303-01-138
INSTALLATION
1. Refer to: Battery (414-01 Battery, Mounting
and Cables, Removal and Installation).
2. Refer to: Cowl Panel Grille (501-02 Front
End Body Panels, Removal and
Installation).
68.
E79327

Procedures).
70. Refer to: Power Steering System Filling (211-00
Steering System - General Information,
2008.50 Kuga 8/2011
G1191241en

TO MODEL INDEX
303-03-1
Engine Cooling
303-03-1
SECTION 303-03 Engine Cooling

CONTENTS
PAGE

Engine Cooling 2.5L Duratec (147kW/200PS) - VI5 (Component Location).................
Engine Cooling 2.5L Duratec (147kW/200PS) - VI5 (Overview)....................................
Auxiliary coolant pump.......................................................................................................
303-03-2
303-03-3
303-03-3

Engine Cooling...................................................................................................................
303-03-4
303-03-4
GENERAL PROCEDURES
Cooling System Draining and Vacuum Filling.....................................................................
Draining..............................................................................................................................
Evacuating and Filling........................................................................................................
Radiator Lower Mounting Repair........................................................................................
303-03-5
303-03-5
303-03-6
303-03-7

Coolant Pump 2.5L Duratec (147kW/200PS) - VI5...................................
Cooling Fan Motor and Shroud 2.5L Duratec (147kW/200PS) - VI5.........
Radiator 2.5L Duratec (147kW/200PS) - VI5.............................................
Thermostat 2.5L Duratec (147kW/200PS) - VI5........................................
Thermostat Housing 2.5L Duratec (147kW/200PS) - VI5..........................
(24 404 0)
(24 222 0)
(24 254 0)
(24 454 0)
(24 001 0)
303-03-10
303-03-11
303-03-14
303-03-19
303-03-20

TO MODEL INDEX
Engine Cooling
303-03-2
303-03-2
Engine Cooling 2.5L Duratec (147kW/200PS) - VI5

Component Location
5
4
6
E105244
Item
Description
Cooling fan motor
Thermostat housing
Coolant pump
2008.50 Kuga 8/2011
Item
Description
Auxiliary coolant pump

Comments:
Vehicles equipped with a trailer coupling
or additional heating
Turbocharger coolant connections
Oil Cooler
G1088832en

TO MODEL INDEX
303-03-3
Engine Cooling
303-03-3
Engine Cooling 2.5L Duratec (147kW/200PS) - VI5 Overview

Auxiliary coolant pump
An electrically operated auxiliary coolant pump is
installed on vehicles with a trailer coupling and/or
additional heating. The auxiliary coolant pump
ensures that the coolant is circulated when the
coolant pump (which is driven by the engine) is not
running.
The additional heating uses the auxiliary coolant
pump to circulate hot coolant through the heat
exchanger and the engine.
On vehicles with a trailer coupling the auxiliary
coolant pump is switched on for 6 minutes by the
PCM (powertrain control module) if the coolant
temperature exceeds 106C when the engine is
switched off. This prevents the coolant circuit from
overheating. This could happen particularly if the
engine is switched off after towing a heavy trailer
up a steep hill before there has been sufficient time
for cooling.
2008.50 Kuga 8/2011
G1088220en

TO MODEL INDEX
Engine Cooling
303-03-4
303-03-4
Engine Cooling
Pressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396

303-396-09
E55030

Mechanical
Coolant leaks
Gaskets/seals
Core plug(s)
Hose(s)/hose joints
Coolant expansion
tank cap and seal(s)
Coolant expansion
tank
Radiator
Coolant pump
Thermostat
Heater core
Exhaust gas recirculation (EGR) cooler
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Engine coolant
temperature (ECT)
sensor
Cooling fan motor
Cooling fan module
Powertrain control
module (PCM)
Coolant shut off
valve
Coolant degas shut
off valve

2008.50 Kuga 8/2011
G1058974en

TO MODEL INDEX
Engine Cooling
303-03-5
303-03-5
GENERAL PROCEDURES
Cooling System Draining and Vacuum Filling

General Equipment
Cooling System Vacuum Tester and Refiller

Fluid Container
4.
Materials
Name
Antifreeze Super Plus
Premium
Specification
WSS-M97B44-D / 4U7J19544-AA2A
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
E65299
5.


escaping fluid.
Use a suitable coolant hose to drain the coolant.
2.

Loosen: 4 turn(s)
Release the cooling system pressure by slowly

turning the coolant expansion tank cap between
2 and 3 turns.
E97501
E68577
6.
E97501
2008.50 Kuga 8/2011
G1034816en

TO MODEL INDEX
Engine Cooling
303-03-6
303-03-6
GENERAL PROCEDURES
7.
4. 2. Open the valve until the specificied vacuum

is achieved.
-0.85 bar
-0.95 bar
E65299
6-10 bar
E96740
Evacuating and Filling

1. If the cooling system was completely drained,
fill the fluid container with the full cooling
system fill capacity plus 0.5L of additional
coolant.
Material: Antifreeze Super Plus Premium
(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
If the cooling system was partially drained,
fill the fluid container with the removed and
spilled amount of coolant plus 1.0L of
additional coolant. When in doubt always use
the full cooling system fill capacity plus 0.5L
of additional coolant.
Material: Antifreeze Super Plus Premium
(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
2. General Equipment: Cooling System Vacuum
Tester and Refiller
3. 1. Close the valve, install the coolant hose and
place it into the fluid container.
2. Close the valve and connect the compressed
air hose.
5. Open the valve until the coolant reservoir

fluid level is at the MAX mark.
If no coolant is visible in the coolant
expansion tank, add 2.0L of coolant to the
fluid container and repeat the evacuating and
filling procedure.
E96741
6.
2
1
E68577
E96739
2008.50 Kuga 8/2011
G1034816en

TO MODEL INDEX
303-03-7
Engine Cooling
303-03-7
GENERAL PROCEDURES
Radiator Lower Mounting Repair

General Equipment
5 mm Drill Bit
4.
Cable Ties
Flat File
E98184
5.
E100039

x4
3.
E100040
6. 1. General Equipment: Flat File

2. General Equipment: 5 mm Drill Bit
E98183
2008.50 Kuga 8/2011
G1062292en
303-03-8

TO MODEL INDEX
Engine Cooling
303-03-8
GENERAL PROCEDURES
2
5 mm
E87749
7.
E87750
2008.50 Kuga 8/2011
G1062292en

TO MODEL INDEX
303-03-9
Engine Cooling
303-03-9
GENERAL PROCEDURES
8. Torque: 25 Nm
x4
E100040
9.
E98184
10.
E98183
11. Remove the cable ties securing the radiator and

condenser assembly.
2008.50 Kuga 8/2011
G1062292en

TO MODEL INDEX
Engine Cooling
303-03-10
303-03-10
Coolant Pump 2.5L Duratec (147kW/200PS) - VI5(24 404 0)

General Equipment
Trolley Jack
6. Torque: 17 Nm
Removal
1. Drain the cooling system.
x3

Procedures).
E63856
2. Remove the timing belt.

Refer to: Timing Belt (303-01 Engine - 2.5L
Installation).
3.
CAUTION: Use a wooden block to

protect the oil pan when supporting the
engine.
Position the trolley jack with the wooden block
under the oil pan. Raise the trolley jack until the
front of the engine is free from load and the
coolant pump bolts can be accessed.
Installation
final tightening.

4. Torque: 17 Nm
x4
E63823
5. Lower the engine.

2008.50 Kuga 8/2011
G544632en

TO MODEL INDEX
303-03-11
Engine Cooling
303-03-11
Cooling Fan Motor and Shroud 2.5L Duratec (147kW/200PS)

- VI5(24 222 0)
4.
Removal
2.
E112584
5.
E98183
3.
E112335
6. Torque: 25 Nm
E98184
2008.50 Kuga 8/2011
G1156382en
303-03-12

TO MODEL INDEX
Engine Cooling
303-03-12
x2
x2
E112585
7.
E112336
2008.50 Kuga 8/2011
G1156382en

TO MODEL INDEX
303-03-13
Engine Cooling
303-03-13

Installation
2008.50 Kuga 8/2011
G1156382en

TO MODEL INDEX
303-03-14
Engine Cooling
303-03-14
Radiator 2.5L Duratec (147kW/200PS) - VI5(24 254 0)

General Equipment
Cable Ties
3. Refer to: Charge Air Cooler (303-12 Intake Air

Installation).
Removal

Procedures).

5. Torque: 25 Nm
1.
x2
x2
E112625
E112311

damaged.
2.
E99980
E112335

2008.50 Kuga 8/2011
G1156381en

TO MODEL INDEX
Engine Cooling
303-03-15
303-03-15
1
2
2
E112626
All vehicles
Remover/Installer
2008.50 Kuga 8/2011
G1156381en

TO MODEL INDEX
Engine Cooling
303-03-16
303-03-16
1
2
E112764
9. Torque: 5 Nm
E99965
2008.50 Kuga 8/2011
G1156381en

TO MODEL INDEX
303-03-17
Engine Cooling
303-03-17
2
E99981
12.
11.
E112627
2008.50 Kuga 8/2011
G1156381en

TO MODEL INDEX
303-03-18
Engine Cooling
303-03-18
1
2
E99754
Installation
2008.50 Kuga 8/2011
G1156381en

TO MODEL INDEX
Engine Cooling
303-03-19
303-03-19
Thermostat 2.5L Duratec (147kW/200PS) - VI5(24 454 0)

5.
Removal
Procedures).
Installation).
3.
E64640
Installation
E64638
4. Torque: 8 Nm
x3
E64639
2008.50 Kuga 8/2011
G962443en

TO MODEL INDEX
Engine Cooling
303-03-20
303-03-20
Thermostat Housing 2.5L Duratec (147kW/200PS) VI5(24 001 0)

Removal
Procedures).
Installation).
3. Torque: 17 Nm
2
4
1
x3
E63828
4.
E67780
Installation
2008.50 Kuga 8/2011
G962444en
Fuel Charging and

TO MODEL INDEX
Controls 2.5L Duratec (147kW/200PS) -
303-04A-1
VI5
303-04A-1
SECTION 303-04A Fuel Charging and Controls 2.5L Duratec

(147kW/200PS) - VI5

CONTENTS
PAGE

Fuel Charging and Controls................................................................................................
303-04A-2

Fuel Charging and Controls................................................................................................
303-04A-4
Symptom Chart................................................................................................................... 303-04A-4
Fuel Injectors......................................................................................................................
Throttle Body.................................................................................................. (23 198 0)
Fuel Rail..............................................................................................................................
303-04A-22
303-04A-23
303-04A-24
Fuel Charging and

303-04A-2

TO MODEL INDEX
303-04A-2
VI5
Fuel Charging and Controls

1
E64777
2008.50 Kuga 8/2011
G510053en
Fuel Charging and

303-04A-3

TO MODEL INDEX
Controls 2.5L Duratec (147kW/200PS) VI5
303-04A-3

Item
Description
Fuel Injectors
Valve
Fuel rail
Throttle body
Fuel tank to fuel rail fuel supply line
2008.50 Kuga 8/2011
G510053en
Fuel Charging and

TO MODEL INDEX
303-04A-4
303-04A-4
VI5
Fuel Charging and Controls

General Equipment

Mechanical
Electrical
Fuel leaks
Loose or corroded
connector(s)
Blocked or contaminated fuel filter
Wiring harness
Damaged fuel
Fuel injector(s)
supply manifold
Damaged fuel line
connections
Damaged vacuum
hoses
Fuel rail pressure
sensor

system.

equipment.
Symptom Chart
Symptom
Engine does not crank
Possible Sources
PATS.
Action
CHECK the PATS LED extinguishes within 3 seconds when
the ignition is turned on.
REFER to: Anti-Theft - Passive
(419-01 Anti-Theft - Passive,
Engine cranks but does not

start
Starting system.
REFER to: Starting System

(303-06 Starting System 2.5L Duratec (147kW/200PS)
Ignition switch.
REFER to the Wiring Diagrams.
Powertrain control module

(PCM).
Carry out a full engine

diagnosis using the guided
diagnostic menu in the Ford
Inertia fuel shutoff (IFS) switch. RESET the IFS switch.

Low fuel system pressure.
2008.50 Kuga 8/2011
Check the fuel system pressure.
G1183441en
Fuel Charging and

303-04A-5

TO MODEL INDEX
303-04A-5
VI5

Symptom
Possible Sources
Action
Fuel lines damaged or blocked. INSPECT the fuel lines.

necessary. TEST the system
for normal operation.
Fuel pump and sender unit.
REFER to: Fuel Pump and

Sender Unit - 2.5L Duratec
(147kW/200PS) - VI5 (310-01
Fuel Tank and Lines,
Crankshaft position (CKP)

sensor.

Camshaft position (CMP)

sensor.

PCM.

Fuel rail fuel pressure sensor. Carry out a full engine

Fuel injectors.
INSPECT the fuel injectors.

CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (30304 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
CHECK the valve timing.

(147kW/200PS) - VI5,
Low cylinder compression.
TEST the cylinder compression.

REFER to: Engine (303-00
Engine System - General
Testing).
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-6

TO MODEL INDEX
303-04A-6
VI5

Symptom
Poor starting
Possible Sources
Action
Fuel system leak.
CHECK the system for fuel

leak(s). REPAIR the system as
necessary.
Fuel system restriction.
INSPECT the fuel system.

Air cleaner element blocked.
INSTALL a new air cleaner

element.
Incorrect engine oil.
INSTALL a new engine oil filter

and engine oil.
Incorrect power steering fluid. DRAIN and REFILL the power

steering system with the correct
fluid.
System Filling (211-00
CKP sensor.

Engine coolant temperature

(ECT) sensor.

Fuel injector(s).

(147kW/200PS) - VI5,

2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-7

TO MODEL INDEX
303-04A-7
VI5

Symptom
Possible Sources
Catalytic converter blocked.
Action
REMOVE and visually
INSPECT the catalytic
converter as necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System 2.5L Duratec (147kW/200PS)
TEST the engine cylinder

compression.
Testing).
Engine starts but immediately Air cleaner element blocked.

stops
Poor idling
2008.50 Kuga 8/2011

element.
CKP sensor.

CMP sensor.

PCM.

Fuel system restriction.
INSPECT the fuel system.


element.
G1183441en
Fuel Charging and

303-04A-8

TO MODEL INDEX
303-04A-8
VI5

Symptom
Possible Sources
Action
Incorrect or contaminated fuel. CHECK for signs of contamination such as strange odors from
the fuel tank.
If contaminated fuel is found,
DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System General Information, General
Procedures).
(147kW/200PS) - VI5,
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04
Fuel Charging and Controls 2.5L Duratec (147kW/200PS)
Fuel injectors.

(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
CKP sensor.

Knock sensor (KS).

G1183441en
Fuel Charging and

303-04A-9

TO MODEL INDEX
303-04A-9
VI5

Symptom
Possible Sources
Action
Fuel injection supply manifold Carry out a full engine

fuel pressure sensor.
Engine stumbling
Engine ignition.

Fuel injectors.

(147kW/200PS) - VI5,

Engine lacks power
Engine ignition.

Brakes binding.
CHECK the braking system.

Testing).
Vehicle overloaded, or
ADVISE the customer about
excessive wind resistance (roof
the effects of overloading the
racks, towing etc).
vehicle and wind resistance on
the fuel consumption.

element as necessary.
Kinked or restricted fuel lines. INSPECT the fuel lines.

2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-10

TO MODEL INDEX
303-04A-10

Symptom
Possible Sources
Action
the fuel tank.
Procedures).
ECT sensor.

Fuel injectors.

(147kW/200PS) - VI5,


(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-11

TO MODEL INDEX
303-04A-11

Symptom
Possible Sources
Action
CHECK the cylinder compression.
Testing).
REMOVE and visually

converter for damage. INSTALL
a new catalytic converter as
necessary.
Black smoke at idle

Fuel injectors.

(147kW/200PS) - VI5,
ECT sensor.


REMOVE and visually

necessary.
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-12

TO MODEL INDEX
303-04A-12

Symptom
Possible Sources
Action
(147kW/200PS) - VI5,
Excessive black smoke during Air cleaner element blocked.

acceleration

the fuel tank.
Procedures).
CKP sensor.

KS.

Fuel injectors.

(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-13

TO MODEL INDEX
303-04A-13

Symptom
Possible Sources
Action

REMOVE and visually

necessary.
Black smoke at cruising speeds Air cleaner element blocked.

element.
ECT sensor.

Fuel injectors.

(147kW/200PS) - VI5,

REMOVE and visually

necessary.
Blue smoke
2008.50 Kuga 8/2011
Engine burning oil.
CARRY OUT a controlled oil

consumption test over 1000 km
(600 miles). CONFIRM that the
oil consumption is less than 0.1
litre per 1000 km (600 miles).
G1183441en
Fuel Charging and

303-04A-14

TO MODEL INDEX
303-04A-14

Symptom
Possible Sources
Action
the fuel tank.
Procedures).
(147kW/200PS) - VI5,
Positive crankcase ventilation INSPECT for visible signs of
(PCV) system.
damage or blockage. CLEAN,
REPAIR or INSTALL new parts
as necessary.
Worn or damaged valve
REMOVE the cylinder head.
guide(s), piston ring(s), cylinder
INSPECT the cylinder head,
bore(s), cylinder head or
pistons and cylinder bores for
gasket.
signs of wear or damage.
REFER to: Cylinder Head (30301 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-15

TO MODEL INDEX
303-04A-15

Symptom
White smoke
Possible Sources
Action
the fuel tank.
Procedures).
(147kW/200PS) - VI5,
Coolant in the combustion
chamber.
CARRY OUT a cooling system

pressure test.
REFER to: Engine Cooling
cylinder head gasket and
cylinder bores for wear or
damage.
(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-16

TO MODEL INDEX
303-04A-16

Symptom
Engine misfire
Possible Sources
Engine ignition.
Action
the fuel tank.
Procedures).
Engine operating temperature REFER to: Engine Cooling

too high.
2008.50 Kuga 8/2011
ECT sensor.

CKP sensor.

CMP sensor.

KS.

G1183441en
Fuel Charging and

303-04A-17

TO MODEL INDEX
303-04A-17

Symptom
Possible Sources
Fuel injectors.
Action
(147kW/200PS) - VI5,

CHECK the engine compression.

Testing).
Worn or damaged valve(s),

tappet(s) or camshaft(s).

valves, tappets and camshafts
for signs of wear or damage.
(147kW/200PS) - VI5,
Damaged cylinder head gasket. REMOVE the cylinder head.

INSPECT the cylinder head
gasket and cylinder bores for
wear or damage.
(147kW/200PS) - VI5,
Engine knock at idle
2008.50 Kuga 8/2011
Low engine oil level.
CHECK the engine oil level.

REFILL as necessary.
G1183441en
Fuel Charging and

303-04A-18

TO MODEL INDEX
303-04A-18

Symptom
Possible Sources
Action
the fuel tank.
Procedures).
(147kW/200PS) - VI5,
KS.

CKP sensor.

Fuel injector(s).

(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

303-04A-19

TO MODEL INDEX
303-04A-19

Symptom
Possible Sources
Action
(147kW/200PS) - VI5,
Excessive carbon build up.

INSPECT the cylinder head
and pistons for signs carbon
build up.
(147kW/200PS) - VI5,
Worn or damaged oil pump.

INSPECT the engine compon Worn or damaged timing chain
ents.
or sprocket.
Major mechanical engine
failure.
Engine knock during accelera- KS.
tion
Fuel injectors.

(147kW/200PS) - VI5,
Excessive fuel consumption
Major mechanical engine

failure.

Testing).
Brakes binding.
CHECK the braking system.

Testing).
Vehicle overloaded, or
ADVISE the customer about
excessive wind resistance (roof
the effects of overloading the
racks, towing etc).
vehicle and wind resistance on
the fuel consumption.
2008.50 Kuga 8/2011

element.
G1183441en
Fuel Charging and

TO MODEL INDEX
303-04A-20
303-04A-20
VI5

Symptom
Possible Sources
Action
Fuel system leak(s).
CHECK the system for fuel

leak(s). REPAIR or INSTALL
new parts as necessary.
Incorrect engine oil.
INSTALL a new oil filter and

engine oil.
Generator.

equipment.
Slipping clutch.
ECT sensor.

Fuel injectors.

(147kW/200PS) - VI5,
PCM calibration.
Using the Ford diagnostic

equipment, CHECK for the
availability of a calibration
update.

(147kW/200PS) - VI5,
CHECK the engine compression.

Testing).
Engine cuts out during hard

acceleration
2008.50 Kuga 8/2011
CMP sensor.

CKP sensor.

G1183441en
Fuel Charging and

303-04A-21

TO MODEL INDEX
303-04A-21

Symptom
Possible Sources
Action

2008.50 Kuga 8/2011
G1183441en
Fuel Charging and

TO MODEL INDEX
303-04A-22
VI5
303-04A-22
Fuel Injectors
Materials
Name
Engine Oil - 5W-30
Specification
WSS-M2C911-A
Removal
1. Refer to: Fuel Rail (303-04 Fuel Charging and
Controls - 2.5L Duratec (147kW/200PS) - VI5,
2. 1. Torque: 10 Nm
4. Material: Engine Oil - 5W-30
(WSS-M2C911-A) engine oil
1
E64170
Installation
2008.50 Kuga 8/2011
G544636en
Fuel Charging and

TO MODEL INDEX
303-04A-23
303-04A-23
VI5
Throttle Body(23 198 0)

3.
Removal
1. Remove the right-hand side headlamp
assembly.
2.
E101067
E74132

damaged.
Torque: 10 Nm
x4
E74133
Installation
2. NOTE: Make sure that the pedals remain in the
rest position.
Turn the ignition key to position II and wait for
one minute to initialize the throttle body.
2008.50 Kuga 8/2011
G1079056en
Fuel Charging and

TO MODEL INDEX
303-04A-24
303-04A-24
VI5
Fuel Rail
Removal
6.

Operation).

residue.
Torque: 4 Nm

Installation).
E63576
7.
5. Torque: 10 Nm

residue.
x2
E92954
E64164
8.

residue.
E64165
2008.50 Kuga 8/2011
G1079057en
Fuel Charging and

303-04A-25

TO MODEL INDEX
303-04A-25
VI5

9. Torque: 10 Nm
10. 1. Torque: 2 Nm
4.
escaping fluid.
Torque: 10 Nm
E64166
3
2
x2
x5
E93083
Installation
2008.50 Kuga 8/2011
G1079057en
Fuel Charging and

303-04B-1

TO MODEL INDEX
Controls - Turbocharger
2.5L Duratec (147kW/200PS) - VI5
303-04B-1
SECTION 303-04B Fuel Charging and Controls Turbocharger 2.5L Duratec (147kW/200PS) - VI5
CONTENTS
PAGE

Turbocharger (Component Location)..................................................................................
Turbocharger (Overview)....................................................................................................
Turbocharger(s)..................................................................................................................
Turbocharger (System Operation and Component Description)........................................
System Diagram.................................................................................................................
Turbocharger(s)..............................................................................................................
Turbocharger boost pressure control..............................................................................
Recirculated air valve.....................................................................................................
Wastegate control valve..................................................................................................
Recirculated air valve.....................................................................................................
303-04B-2
303-04B-4
303-04B-4
303-04B-5
303-04B-5
303-04B-6
303-04B-6
303-04B-6
303-04B-7
303-04B-7
303-04B-7
303-04B-7

Turbocharger......................................................................................................................
303-04B-9
Inspection and Verification.................................................................................................. 303-04B-9
Turbocharger.................................................................................................. (23 612 0)
303-04B-11
Fuel Charging and

303-04B-2

TO MODEL INDEX
303-04B-2
Turbocharger Component Location
E97600
Item
Description
Item
Description
Turbocharger heat shield
TC (turbocharger)
from air filter
to intercooler
Exhaust manifold
2008.50 Kuga 8/2011
G1032424en
Fuel Charging and

303-04B-3

TO MODEL INDEX
303-04B-3
10
E97592
Item
Description
Item
Description
Exhaust manifold
Turbo boost pressure controller
PCV (positive crankcase ventilation)- hose

Comments:
to cylinder head
Oil supply pipe - TC
Wastegate control valve
TC
Comments:
Contains the recirculated air valve
Coolant supply pipe
10
Oil return pipe - TC
Vacuum line - recirculated air valve

Comments:
to intake manifold
Coolant return pipe
2008.50 Kuga 8/2011
G1032424en
Fuel Charging and

303-04B-4

TO MODEL INDEX
303-04B-4
Turbocharger Overview
Turbocharger(s)
CAUTION: Do not switch off the engine
while it is running at high speed. If the
engine is switched off while it is running
at high speed, the turbocharger will
continue to run after the engine oil
pressure has already dropped to zero. This
will cause premature wear in the
turbocharger bearings.
A TC consists of an exhaust turbine located in the
exhaust gas flow, this turbine is connected to a
compressor by a shaft. The turbine is made to
rotate by the exhaust gas flow from the engine and
thus drives the compressor. The compressor
increases the pressure in the engine intake tract
so that a greater mass of air enters the cylinder
during the intake stroke.
never be attempted. A red colored seal is applied

to the adjustment nut of the operating rod, in order
to monitor the factory setting of the boost pressure.
The bearings of the TC are lubricated with engine
oil. The engine oil passes from the cylinder block
through the oil supply pipe to the TC. The oil is
returned to the oil pan through the oil return pipe,
The TC is cooled by the engine coolant circuit.
When installing hoses and lines, make certain that
their ends are free of oil residues and dirt.
The turbine housing of the TC is integrated into the

exhaust manifold. This construction offers
thermodynamic advantages compared with the
usual construction, the maximum exhaust
temperature is up to 1050C.
The maximum boost pressure is 0.65 bar.
The exhaust manifold is secured to the exhaust
side of the cylinder head with 12 self-locking nuts.
The exhaust manifold gasket is a multi-layer steel
gasket and cannot be reused. In order to
compensate for the thermal expansion of the
exhaust manifold, the flange of the TC is provided
with two grooves.
The TC and the exhaust manifold are joined by a
hose clip. The hose clip must not be loosened or
removed. The TC and the exhaust manifold are
not available as separate replacement parts,
exchange is only possible as a complete unit.
The turbocharger heat shield is secured to the
exhaust manifold by four bolts. Two of the bolts
have spring washers underneath their heads.
During removal, make a note of the installation
location of the spring washers to refer to during
installation.
The recirculated air valve is built into the TC
housing and cannot be changed.
The Ford diagnostic unit can test the operation of
the wastegate control valve using actuator
diagnosis.
The boost pressure regulator is set in the factory.
Adjustments to the boost pressure regulator must
2008.50 Kuga 8/2011
G1032425en
Fuel Charging and

303-04B-5

TO MODEL INDEX
303-04B-5
Turbocharger System Operation and Component Description

System Diagram
15
14
10
13
11
12
E98961
Item
Description
from exhaust manifold
Pilot pressure
2008.50 Kuga 8/2011
Item
Description

7)
Comments:
closed when de-energised
G1032426en
Fuel Charging and

303-04B-6

TO MODEL INDEX
303-04B-6

Item
Description
Item
Description
PWM (pulse width modulation) signal

Comments:
from PCM (powertrain control module)
10
Recirculated air valve

7)
Atmospheric pressure
11
Vacuum line, recirculated air valve
Turbocharger boost pressure.
12
to intake manifold
from air filter
13
Throttle plate
Intake air
14
Compressor
15
Turbine
System Operation
Turbocharger(s)
The TC consists of a turbine and a compressor.
The turbine is driven by the exhaust gas flow. A
common shaft drives the compressor and this then
compresses the intake air.
Turbocharger boost pressure control
2
3
E98942
Item
Description
Atmospheric pressure
Turbocharger boost pressure.
Pilot pressure
The size of the TC is designed to produce a charge

effect even at medium engine speeds and lower
exhaust gas flows. This means that, when the
2008.50 Kuga 8/2011
engine speed is high and there is a large amount

of exhaust gas, either the boost pressure of the
TC will become too high or its speed will be too
high. The TC must therefore be regulated. The
best regulation is achieved by an electronically
controlled wastegate control valve. The wastegate
control valve controls the pressure on the
membrane in the boost pressure regulator.
The wastegate control valve is actuated by the
PCM with a PWM signal according to a map. The
boost pressure is applied to the wastegate control
valve via the pressure line from the compressor.
This pressure is passed to the boost pressure
regulator via the wastegate control valve. This
opens the bypass valve using a linkage. This
channels a portion of the exhaust gases around
the turbine. If the wastegate control valve is
actuated by the PCM, a bypass is opened in the
wastegate control valve. This causes the pressure
which can act on the membrane in the boost
pressure regulator to be reduced. This occurs until
the boost pressure has reached a set value. By
actuation with a PWM signal, it is also possible to
partially open or close the wastegate control valve.
This results in a constant boost pressure and
therefore high torque over a wide range of engine
speeds.
Because the PCM calculates the boost pressure
using the signal from the boost pressure sensor
and the IAT (intake air temperature) sensor, the
atmospheric pressure and the temperature are
automatically compensated for. Because of this
compensation, the engine power is not noticeably
affected by variations in atmospheric temperature
or pressure.
G1032426en
Fuel Charging and

303-04B-7

TO MODEL INDEX
303-04B-7

3
1
E97052
Item
Description
E98852
Vacuum hose to intake manifold
Air ingress
from turbocharger (boost pressure)
Air discharge
from turbocharger (atmospheric pressure)
to boost pressure regulator (control

pressure)
If the throttle valve is closed quickly, the moving

air column hits the throttle valve. The air column
is reversed, flows back onto the rotating impeller
of the TC and powerfully decelerates it. A
recirculated air valve is installed to prevent this
deceleration of the impeller and thus allow the TC
to respond faster. The recirculated air valve is
controlled via a vacuum line which is connected to
the intake manifold. When the throttle valve is
suddenly closed, a high vacuum occurs in the
intake manifold. This opens the recirculated air
valve and the compressed air is returned to a point
before the compressor. This causes the speed of
the turbocharger to drop less rapidly and the boost
pressure can build up more rapidly when the
accelerator pedal is pressed again.
Item
Description
The wastegate control valve operates as a cycle

valve. The pressure acting on the membrane in
the boost pressure regulator is controlled by
appropriate pulsing of the wastegate control valve.
The pressure acting on the membrane in the boost
pressure regulator is reduced when the wastegate
control valve opens.
The operating voltage of the wastegate control
valve is 12V.
The internal resistance of the wastegate control
valve is 28.5 1.5 Ohms.
The operating states are:
De-energised: gate open between 1 and 3
Boost pressure high > wastegate control
valve closed > boost pressure regulator open
> turbine receives restricted exhaust gas
flow.
Energised: gate open between 2 and 3
Boost pressure low > wastegate control valve
open > boost pressure regulator closed >
turbine receives full exhaust gas flow.
2008.50 Kuga 8/2011
G1032426en
Fuel Charging and

303-04B-8

TO MODEL INDEX
303-04B-8

E98940
The recirculated air valve is a vacuum-controlled

spring/membrane valve. If vacuum is applied to
the recirculated air valve, the piston is pulled in
against the spring pressure and a bypass bore is
opened.
As the vacuum decreases, the spring pressure
prevails and the piston re-closes the bypass bore.
2008.50 Kuga 8/2011
G1032426en
Fuel Charging and

303-04B-9

TO MODEL INDEX
303-04B-9
Turbocharger
Hand Vacuum/Pressure
Pump
416 - D001 (23 - 036A)
connections, locate and rectify the source. Do not

install a new turbocharger due to an oil leak.
Mechanical
23036A
Fuel Pressure Gauge

310-053 (23-046)
23046

NOTE: It is normal for a small amount of
combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through
the positive crankcase ventilation (PCV) system,
which incorporates an crankcase vent oil separator.
Some engine oil, in the form of a vapor is carried
into the air intake system with the blow-by gases
(this engine oil also contributes to valve seat
durability). This means that oil will collect inside
the air intake components and the turbocharger.
This is not an indication that the turbocharger oil
seal has failed. The turbocharger oil seal will not
fail unless the bearings fail first, which will cause
the turbocharger to become noisy or seize. Do not
install a new turbocharger due to oil inside the
turbocharger or the air intake components. If a leak
is detected in the oil supply or return tubes or
Electrical
Oil leak(s)
Wiring harness
Air cleaner element Boost control
solenoid valve
Air cleaner outlet
pipe
Powertrain control
module (PCM)
Air cleaner intake
pipe
Turbocharger oil
supply or oil return
tube
Turbocharger intake
pipe
Turbocharger
vacuum diaphragm
unit
Turbocharger
housing
Charge air cooler
Charge air cooler
intake pipe and
hose(s)
Charge air cooler
outlet pipe and
hose(s)
NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.
2008.50 Kuga 8/2011
G1183442en
Fuel Charging and

303-04B-10

TO MODEL INDEX
303-04B-10

Symptom
Blue smoke with excessive
turbocharger noise
Possible Sources
Action
Turbocharger compressor
INSPECT the turbocharger for
rubbing on housing walls.
signs of damage. INSTALL a
Turbocharger turbine rubbing
new turbocharger as neceson housing walls.
sary.
Turbocharger bearings and oil
REFER to: Turbocharger (303seal(s).
04 Fuel Charging and
Turbocharger oil supply tube
Controls - Turbocharger blocked or damaged.
2.5L Duratec (147kW/200PS)
Blue smoke without excessive Turbocharger oil return tube

turbocharger noise
blocked or damaged.
Check the oil return tube for

blockage or damage, INSTALL
a new oil return tube as necessary.
Poor engine performance
Vacuum diaphragm unit

vacuum line(s).
CHECK all vacuum line(s) are

installed and no signs of air
leaks are present. REPAIR as
necessary.
Charge air cooler system.
CHECK the charge air cooler,

charge air cooler pipes and
charge air cooler hoses for
leaks and obstructions.
REPAIR as necessary.
Air cleaner intake pipe.
CHECK the air cleaner intake

pipe for obstruction. REPAIR
the necessary.
Unauthorized adjustment of the The turbocharger boost presvacuum diaphragm unit actusure is factory set and must not
ator rod.
be adjusted. CHECK the paint
seal on the vacuum diaphragm
unit actuator rod has not been
broken. If the paint seal has
been broken, INSTALL a new
turbocharger.
Vacuum diaphragm unit actuator rod.
2008.50 Kuga 8/2011
CHECK the vacuum diaphragm

unit actuator rod moves freely,
If the vacuum diaphragm unit
actuator rod does not move
freely. CHECK for signs of
damage or signs of foreign
material. REPAIR as necessary.
G1183442en
Fuel Charging and

303-04B-11

TO MODEL INDEX
303-04B-11
Turbocharger(23 612 0)
5.
General Equipment
Cable Ties
Materials
Name
Grease KS-PS

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
Specification
3
1
Removal
Procedures).
2
E68504
6.
1

4.
E67948
E65070
7. 1. Torque: 26 Nm
2. Torque: 26 Nm
Torque: 38 Nm
E112143
2008.50 Kuga 8/2011
G1079058en
Fuel Charging and

303-04B-12

TO MODEL INDEX
303-04B-12

8. Torque: 24 Nm
11.

residue.
Torque: 4 Nm
E63820
E112607
12.
9.

residue.
TIE0014991
14. Torque: 28 Nm
E66726
10. Torque: 17 Nm
E66825
E63819
2008.50 Kuga 8/2011
G1079058en
Fuel Charging and

303-04B-13

TO MODEL INDEX
303-04B-13

15.
17.

Torque: 50 Nm
E66050
x2
16. Torque: 24 Nm
E112253

Remover/Installer
Torque: 38 Nm
E112254
E66826
2008.50 Kuga 8/2011
G1079058en
Fuel Charging and

303-04B-14

TO MODEL INDEX
303-04B-14

19. Torque: 12 Nm
20. Torque: 24 Nm
x2
E66829
x1
2
E112772
Installation
2008.50 Kuga 8/2011
G1079058en

TO MODEL INDEX
303-05-1
Accessory Drive 2.5L Duratec (147kW/200PS) - VI5
303-05-1
SECTION 303-05 Accessory Drive 2.5L Duratec (147kW/200PS) - VI5

CONTENTS
PAGE

Accessory Drive..................................................................................................................
303-05-2

Accessory Drive..................................................................................................................
Accessory Drive Belt Concerns..........................................................................................
Symptom Chart...................................................................................................................
Component Tests................................................................................................................
303-05-4
303-05-4
303-05-4
303-05-6
303-05-9

Accessory Drive Belt Tensioner...................................................................... (21 569 0)
Accessory Drive Belt...................................................................................... (21 567 0)
Air Conditioning (A/C) Compressor Belt......................................................... (21 567 0)
Air Conditioning (A/C) Compressor Belt Tensioner............................................................
303-05-11
303-05-12
303-05-13
303-05-14

TO MODEL INDEX
303-05-2
303-05-2
Accessory Drive
E63663
Item
Description
Accessory drive belt
Air conditioning (A/C) compressor belt
2008.50 Kuga 8/2011
G510168en

TO MODEL INDEX
303-05-3
303-05-3
E63662
Item
Description
Generator
Accessory drive belt tensioner
A/C compressor
A/C drive belt tensioner
Crankshaft pulley
2008.50 Kuga 8/2011
G510168en

TO MODEL INDEX
303-05-4
303-05-4
Accessory Drive
damage.
drive belt. Only if the crack is deep enough to reach

the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.

Mechanical
1. Check the accessory drive belt for cracks. If the

damage exceeds the acceptable limit, install a
new accessory drive belt.
Damaged or contaminated accessory drive

belt or air conditioning (A/C) compressor belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt or A/C
compressor belt
Incorrect fitment of the accessory drive belt
or A/C compressor belt
Accessory drive belt tensioner
Accessory drive belt idler pulley
Generator
A/C compressor
A/C compressor belt tensioner
Pulley(s)
Loose hardware
REFER to: Accessory Drive Belt (303-05

Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Installation).
Chunking
Chunking describes the condition where long

lengths of rubber become detached from the ribs
of the accessory drive belt. This is considered to
be a failure of the accessory drive belt.

Accessory Drive Belt Concerns

CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner(s)
or idler pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism, accessory
drive belt tensioner pulley bearing and idler
pulley(s) bearing may occur.
NOTE: All the diagnosis and testing information
contained within this procedure can be used for
the accessory drive belt and the A/C compressor
belt.
Cracking
Accessory drive belts are made from rubber which

hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory
2008.50 Kuga 8/2011
MPZ9632071
2. Check the accessory drive belt for damage. If

any chunks are found to be missing, install a
new accessory drive belt.
Installation).
and/or
Installation).
G1183443en

TO MODEL INDEX
303-05-5
303-05-5

Pilling
Pilling is dust that forms in between the ribs of the

accessory drive belt from rubber that is worn off
the accessory drive belt when it is new. There may
also be loose particles left on the accessory drive
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the accessory
drive belt. This condition will usually clear itself
within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.
and/or
REFER to: Air Conditioning (A/C)
Compressor Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5,
4. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
Installation).
and/or
5. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
accessory drive belt.
Installation).
and/or
6. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
VUE0037805
3. Check the accessory drive belt for pilling. The

condition of the accessory drive belt should be
compared against the illustration.
1. Small scattered pills. Not considered a
concern. No action required.
2. Small scattered pills. Not considered a
concern. No action required.
3. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
Installation).
2008.50 Kuga 8/2011

Installation).
and/or
Incorrect fitment
Accessory drive belt noise can be generated by

the accessory drive belt being incorrectly fitted on
the pulley as shown in the following illustration.
Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
G1183443en

TO MODEL INDEX
303-05-6
303-05-6

VUE0037806
Symptom Chart
Symptom
Accessory drive belt noise
Possible Sources
Accessory drive system
Action
CHECK the system with the
engine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
operation.
Accessory drive belt incorrectly CHECK the accessory drive

installed.
belt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as necessary.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
and/or
REFER to: Air Conditioning
(A/C) Compressor Belt (30305 Accessory Drive - 2.5L
Duratec (147kW/200PS) VI5, Removal and Installation).
operation.
2008.50 Kuga 8/2011
G1183443en

TO MODEL INDEX
303-05-7
303-05-7

Symptom
Possible Sources
Pulley(s).
Action
CHECK the pulley(s) for
damage, freedom of rotation,
stone entrapment and alignment. INSTALL new components as necessary. TEST the
Lubricant or other contamina- CHECK the accessory drive

tion.
belt for contamination or
damage. RECTIFY the source
of the leak and INSTALL a new
- 2.5L Duratec
(147kW/200PS) - VI5,
and/or
operation.
NOTE: Squeal is defined as a
Accessory drive belt tensioner CHECK the accessory drive
continuous shriek, most noticeable
worn, damaged or contaminbelt tensioner for correct operawhen the engine is being accelerated with oil.
tion, damage or contamination.
ated or with electrical load.
REFER to the Accessory Drive
Belt Tensioner Component Test
Accessory drive belt squeal
in this procedure. INSTALL a
new accessory drive belt
tensioner as necessary.
Belt Tensioner (303-05
Accessory Drive - 2.5L
or
(A/C) Compressor Belt
Tensioner (303-05 Accessory
Drive - 2.5L Duratec
(147kW/200PS) - VI5,
operation.
2008.50 Kuga 8/2011
G1183443en

TO MODEL INDEX
303-05-8
303-05-8

Symptom
NOTE: Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt whine
Possible Sources
Action
Poor surface finish on

REMOVE the accessory drive
accessory drive belt idler pulley
belt.
flat surface(s).
- 2.5L Duratec
(147kW/200PS) - VI5,
and/or
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
operation.
Accessory drive belt idler pulley REMOVE the accessory drive
bearing failure.
belt.
- 2.5L Duratec
(147kW/200PS) - VI5,
and/or
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as necessary. TEST the system for
normal operation.
NOTE: Chirp is defined as a twit- Pulley misalignment (usually

tering noise, often intermittent
evident at idle).
Accessory drive belt chirp
2008.50 Kuga 8/2011
CHECK that the accessory

drive belt is running centrally
on the flat pulleys. TEST the
CHECK the pulleys for
excessive end float and bent
flanges.
With the engine running at idle,
use a stethoscope to identify
the source of the noise.
G1183443en

TO MODEL INDEX
303-05-9
303-05-9

Symptom
NOTE: Rattle is defined as a
metallic knocking noise
Accessory drive belt rattle
Possible Sources
Action
Accessory drive belt tensioner CHECK the accessory drive

hitting the end stops.
belt tensioner for correct operation or damage. REFER to the
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a new
accessory drive belt tensioner
as necessary.
Belt Tensioner (303-05
Accessory Drive - 2.5L
or
(A/C) Compressor Belt
Tensioner (303-05 Accessory
Drive - 2.5L Duratec
(147kW/200PS) - VI5,
operation.
Loose components or hardware.
Component Tests
Accessory Drive Belt Tensioner - Static
Check
The accessory drive belt tensioner may be checked
statically as follows:
1. Inspect the area surrounding the accessory
drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt tensioner.
If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
damping mechanism inside may be damaged.
INSTALL a new accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
Installation).
2008.50 Kuga 8/2011
CHECK the components or

hardware for correct installation
and tighten as necessary.
operation.
or
Belt Tensioner (303-05 Accessory Drive - 2.5L
Installation).
2. Detach the accessory drive belt in the area of
the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner
has a damping feature, which is usually a
friction device, therefore some friction within
the system is normal.
Using the correct tool, move the accessory drive
belt tensioner from its relaxed position through
its full stroke and back to the relaxed position
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley
and check for damage, freedom of rotation and
G1183443en

TO MODEL INDEX
303-05-10
303-05-10

alignment. INSTALL a new accessory drive belt
Installation).
or
Installation).
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner.
Installation).
or
Installation).
or
Installation).
2. Excessive accessory drive belt rideout (uneven
depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt
tensioner movement. Check the condition by
installing a new accessory drive belt.
Installation).
and/or
Installation).
Accessory Drive Belt Tensioner - Dynamic

Check
The accessory drive belt tensioner may be checked
dynamically as follows:
1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
Installation).
2008.50 Kuga 8/2011
G1183443en

TO MODEL INDEX
303-05-11
303-05-11
Accessory Drive Belt Tensioner(21 569 0)

Removal
1. Remove the air conditioning (A/C) compressor
belt tensioner.
Refer to: Air Conditioning (A/C) Compressor
Installation).
2. Remove the accessory drive belt.
Refer to: Accessory Drive Belt (303-05
Installation).
3. Torque: 45 Nm
E65525
Installation
1. NOTE: Make sure that the belt tensioner is
aligned to the belt tensioner bracket.
E65526
2008.50 Kuga 8/2011
G544771en

TO MODEL INDEX
303-05-12
303-05-12
Accessory Drive Belt(21 567 0)

Removal
1. Remove the air conditioning (A/C) compressor
belt.
Installation).
2.
E64287
Installation
2008.50 Kuga 8/2011
G543728en

TO MODEL INDEX
303-05-13
303-05-13
Air Conditioning (A/C) Compressor Belt(21 567 0)

Installation
Removal
1. Remove the right-hand front wheel and tire.

2.
E65955
3.
E64285
4.
2
E64286
2008.50 Kuga 8/2011
G545010en

TO MODEL INDEX
303-05-14
303-05-14
Air Conditioning (A/C) Compressor Belt Tensioner

Removal
1. Remove AC compressor belt.
Installation).
2. Torque: 45 Nm
E65527
Installation
1. NOTE: Make sure that the belt tensioner is
aligned to the belt tensioner bracket.
E65528
2008.50 Kuga 8/2011
G546631en

TO MODEL INDEX
303-06-1
Starting System 2.5L Duratec (147kW/200PS) - VI5
303-06-1
SECTION 303-06 Starting System 2.5L Duratec (147kW/200PS) - VI5

CONTENTS
PAGE

Starting System (Component Location)..............................................................................
Starting System (System Operation and Component Description)....................................
System Diagram.................................................................................................................
Smart Start......................................................................................................................
Emergency starting function...........................................................................................
303-06-2
303-06-3
303-06-3
303-06-8
303-06-8
303-06-8

Starting System..................................................................................................................
303-06-9
303-06-9

Starter Motor................................................................................................... (26 204 0)
Start Inhibit Switch..............................................................................................................
303-06-10
303-06-11

TO MODEL INDEX
303-06-2
303-06-2
Starting System Component Location

2.5L Duratec (VI5)
E97220
2008.50 Kuga 8/2011
G1090689en

TO MODEL INDEX
303-06-3
303-06-3
Starting System System Operation and Component Description

System Diagram
Starter system with ignition key
1
2
3
4
9
A
B
10
11
E97384
2008.50 Kuga 8/2011
G1032961en

TO MODEL INDEX
303-06-4
303-06-4

Item
Description
Item
Description
Vehicles with manual transaxle.
Starter relay
If equipped with an automatic transaxle.
Starter motor
Ignition key
Comments:
With transponder for PATS (passive
anti-theft system)
Stoplight Switch
Comments:
10
PATS
Ignition lock
TCM (transmission control module)

Comments:
11
Starting deactivation relay

Comments:
Battery
2008.50 Kuga 8/2011
G1032961en

TO MODEL INDEX
303-06-5
303-06-5

Keyless starting system (vehicles with manual transmission)
5
6
10
9
E97428
2008.50 Kuga 8/2011
G1032961en

TO MODEL INDEX
303-06-6
303-06-6

Item
Description
Start/stop button
CPP (clutch pedal position) switches

Comments:
Switches when the clutch pedal is
operated
Keyless vehicle module
Electronic steering lock with mount passive key and PATS transmitter/receiver
unit
Comments:
for emergency start function
2008.50 Kuga 8/2011
Item
Description
Radio frequency receiver

Comments:
Signal is only executed in GEM
GEM
PCM
Starter relay
Starter motor
10
Battery
G1032961en

TO MODEL INDEX
303-06-7
303-06-7

Keyless starting system (vehicles with automatic transmission)
10
7
11
12
E97429
2008.50 Kuga 8/2011
G1032961en

TO MODEL INDEX
303-06-8
303-06-8

Item
Description
Item
Description
Start/stop button
GEM
Keyless vehicle module
Stoplight Switch
Electronic steering lock with mount passive key and PATS transmitter/receiver
unit
Comments:
for emergency start function
TCM
Starting deactivation relay
PCM
10
Starter relay
11
Starter motor
12
Battery
Radio frequency receiver

Comments:
Signal is only executed in GEM
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
In this case, there is a passive key mount on the

steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
If the engine does not turn or turns only slowly, the

starting process is aborted by the PCM.
The starter is not activated if:
the engine is running (i.e. the engine speed is
above a particular value),
the PATS does not permit the engine to be
started,
the clutch pedal is not operated (vehicles with
manual transmission),
the gear selector level is not set to P or N
(vehicles with automatic transmission),
the brake pedal is not operated (vehicles with
automatic transmission).
Emergency starting function

If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function.
2008.50 Kuga 8/2011
G1032961en

TO MODEL INDEX
303-06-9
303-06-9
Starting System
General Equipment

damage.
Electrical
Fuse(s)
Wiring harness
Relay
Switch(es)
Engine junction box (EJB)
Central junction box (CJB)
Keyless vehicle module (KVM) (if equipped)
Battery
Starter motor

the Ford diagnostic equipment.
2008.50 Kuga 8/2011
G1183444en

TO MODEL INDEX
303-06-10
303-06-10
Starter Motor(26 204 0)

5. Torque: 12 Nm
Removal
Installation).
3.
E64737
6. Torque: 50 Nm
x2
E63784
4. Torque: 10 Nm
E64738
Installation
E63785
2008.50 Kuga 8/2011
G962446en

TO MODEL INDEX
303-06-11
303-06-11
Start Inhibit Switch

Removal
1.
CAUTION: Make sure that the clutch

3
E101868
Installation
1.

2008.50 Kuga 8/2011
G1264759en

TO MODEL INDEX
303-07-1
Engine Ignition 2.5L Duratec (147kW/200PS) - VI5
303-07-1
SECTION 303-07 Engine Ignition 2.5L Duratec (147kW/200PS) - VI5

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
Spark plugs.....................................................................................................................
303-07-2
303-07-2

Engine Ignition....................................................................................................................
Symptom Chart...................................................................................................................
303-07-3
303-07-3
303-07-3

Ignition Coil-On-Plug...................................................................................... (22 414 0)
303-07-4

TO MODEL INDEX
303-07-2
303-07-2
SPECIFICATIONS
Spark plugs
Description
Spark plug gap
mm
0.7
Item
Spark plug
2008.50 Kuga 8/2011
Nm
lb-ft
lb-in
28
G1268535en

TO MODEL INDEX
303-07-3
303-07-3
Engine Ignition
General Equipment

Electrical

damage.
Circuit(s)
Wiring harness
Spark plug(s)
Ignition coil-on-plug(s)

Symptom Chart
Symptom
Engine misfire
Engine stumbling
Engine lacks power
2008.50 Kuga 8/2011
Possible Sources
Action
Spark plug(s).
CARRY OUT a KV test using


equipment.
Circuit(s).
Ignition coil-on-plug(s).
PCM.
PCM calibration.
Spark plug(s).


equipment.
Circuit(s).
PCM.
PCM calibration.
Spark plug(s).

Circuit(s).

equipment.
G323557en

TO MODEL INDEX
303-07-4
303-07-4
Ignition Coil-On-Plug(22 414 0)

3. Torque: 10 Nm
Removal
1.
x8

residue.
E113004
4. 2. Torque: 10 Nm
2
E65070
2.

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
1
E65075
Installation
3
1
2
E68504
2008.50 Kuga 8/2011
G1165594en

TO MODEL INDEX
303-08-1
Engine Emission Control 2.5L Duratec (147kW/200PS) - VI5
303-08-1
SECTION 303-08 Engine Emission Control 2.5L Duratec

(147kW/200PS) - VI5

CONTENTS
PAGE

Engine Emission Control....................................................................................................
2.5L Duratec-ST (VI5)........................................................................................................
303-08-2
303-08-2

Engine Emission Control....................................................................................................
Symptom Chart...................................................................................................................
303-08-4
303-08-4
303-08-4

TO MODEL INDEX
303-08-2
303-08-2
Engine Emission Control

2.5L Duratec-ST (VI5)
Engine Emission Components
E66306
2008.50 Kuga 8/2011
G510285en

TO MODEL INDEX
303-08-3
303-08-3

Item
Description
Intake manifold to turbocharger breather

hose
Crankcase vent oil separator to valve

cover hose
Crankcase vent oil separator to intake

manifold hose
Crankcase vent oil separator
2008.50 Kuga 8/2011
G510285en

TO MODEL INDEX
303-08-4
303-08-4
Engine Emission Control

damage.
Mechanical
Hose(s)/hose joints
Gasket(s)
Positive crankcase
ventilation (PCV)
valve
PCV crankcase vent
oil separator
Turbocharger

Electrical
Electrical
connector(s)
Wiring harness
Fuse(s)
Relay
Powertain control
module (PCM)
Symptom Chart
Symptom
Possible Sources
Excessive crankcase pressure Blocked PCV crankcase vent

oil separator.
Blocked PCV hose.
Engine.
Action
CLEAN or INSTALL new PCV
operation.
Worn or damaged engine
components.
Testing).
Oil in the air intake system
Crankcase vent oil separator.
CLEAN or INSTALL a new

crankcase vent oil separator.
operation.
Turbocharger.
Worn or damaged
turbocharger.
2008.50 Kuga 8/2011
G1183446en

TO MODEL INDEX
303-08-5
303-08-5

Symptom
Possible Sources
Action
Excessive crankcase pressure. Worn or damaged engine

components.
Testing).
2008.50 Kuga 8/2011
G1183446en
Intake Air Distribution

303-12-1

TO MODEL INDEX
and Filtering 2.5L Duratec
(147kW/200PS) - VI5
303-12-1
SECTION 303-12 Intake Air Distribution and Filtering


CONTENTS
PAGE

Intake Air Distribution and Filtering (Component Location)................................................
303-12-2

Intake Air Distribution and Filtering.....................................................................................
Symptom Chart...................................................................................................................
303-12-4
303-12-4
303-12-4

Air Cleaner...................................................................................................... (23 174 0)
Charge Air Cooler........................................................................................... (23 620 0)
303-12-6
303-12-8

303-12-2

TO MODEL INDEX
303-12-2
(147kW/200PS) - VI5
Intake Air Distribution and Filtering Component Location

1
9
8
E105576
Item
Description
Item
Description
Intake manifold
Turbocharger
Air cleaner
Pipe, turbocharger to intercooler
The MAF (mass air flow) sensor
Charge air cooler
Pipe, air filter to turbocharger
Pipe, intercooler to intake manifold
Air Intake manifold
2008.50 Kuga 8/2011
G1079094en

303-12-3

TO MODEL INDEX
303-12-3
(147kW/200PS) - VI5
1
2
E105848
Item
Description
Throttle body mechanism

Comments:
Incorporates the TP (throttle position)
sensor
PCM (powertrain control module) cover
The MAPT (manifold absolute pressure

and temperature) sensor
2008.50 Kuga 8/2011
G1079094en

303-12-4

TO MODEL INDEX
303-12-4
(147kW/200PS) - VI5
Intake Air Distribution and Filtering

Mechanical
Air cleaner element
Air cleaner intake
pipe
Air cleaner outlet
pipe
Charge air cooler
Charge air cooler
intake pipe
Charge air cooler
outlet pipe

Electrical
Mass air flow (MAF)
sensor
Manifold absolute
pressure (MAP)
sensor
Electrical
connector(s)
Symptom Chart
Symptom
Possible Sources
Action
Excessive intake air noise
Detached air cleaner pipe(s). CHECK the pipe(s) for security

Detached turbocharger pipe(s).
and leaks to atmosphere.
Detached charge air cooler
INSTALL new intake air
pipe(s).
operation.
Oil in the air intake system
Blocked or damaged PCV

REFER to: Engine Emission
pipe(s)/hose(s).
Control (303-08 Engine
Blocked or damaged crankcase
Emission Control - 2.5L
vent oil separator.
Water in the air cleaner
2008.50 Kuga 8/2011
Turbocharger.

Air intake pipe splash shield.
CHECK the air intake pipe

splash shield for correct installation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as necessary. TEST the system for
normal operation.
G1183447en

303-12-5

TO MODEL INDEX
303-12-5
(147kW/200PS) - VI5

Symptom
Engine lacks power
Possible Sources
Action
Blocked air cleaner drain.
CHECK the air cleaner drain

for blockage. TEST the system
INSPECT the air cleaner for

signs of blockage. INSTALL a
new air cleaner element as
necessary.
Charge air cooler pipe(s).
INSPECT the charge air cooler

pipes for damage. INSTALL a
new charge air cooler pipe(s)
as necessary.
Charge air cooler blocked.
INSPECT the charge air cooler

for blockage. INSTALL a new
charge air cooler as necessary.
REFER to: Charge Air Cooler
(303-12 Intake Air Distribution
and Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
2008.50 Kuga 8/2011
Fuel charging and controls.
REFER to: Fuel Charging and

Controls (303-04 Fuel Charging and Controls - 2.5L
Turbocharger.

Engine.

Testing).
G1183447en

303-12-6

TO MODEL INDEX
303-12-6
(147kW/200PS) - VI5
Air Cleaner(23 174 0)

General Equipment
Retaining Strap
Trolley Jack
4.

components catch.
Torque: 90 Nm
Removal
1.
15 mm
E106249
2.
E112303
E63329
3.
E112307
2008.50 Kuga 8/2011
G1079095en

303-12-7

TO MODEL INDEX
303-12-7
(147kW/200PS) - VI5

7.
5. Torque: 7 Nm
x4
E65856
All vehicles
8.

components catch.
1
2
E92343

6.
E63326
Installation
1. To install, reverse the removal.
E93509
2008.50 Kuga 8/2011
G1079095en

303-12-8

TO MODEL INDEX
(147kW/200PS) - VI5
303-12-8
Charge Air Cooler(23 620 0)

3.
Removal
2.
E98184
4. Torque: 5 Nm
E98183
E99948
Installation
2008.50 Kuga 8/2011
G1079096en

TO MODEL INDEX
303-13-1
Evaporative Emissions
303-13-1
SECTION 303-13 Evaporative Emissions

CONTENTS
PAGE

Evaporative Emissions.......................................................................................................
303-13-2
303-13-2

TO MODEL INDEX
303-13-2
303-13-2
Mechanical
Electrical
Vacuum line(s)
Fuse(s)
Evaporative emis Wiring harness
sion canister
Electrical
Evaporative emisconnector(s)
sion system hose(s)
Evaporative emission canister purge
valve
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Electronic Engine Controls 2.5L Duratec (147kW/200PS) - VI5
303-14-1
SECTION 303-14 Electronic Engine Controls 2.5L Duratec

(147kW/200PS) - VI5

CONTENTS
PAGE
PAGE 1 OF 2

Electronic Engine Controls (Component Location).............................................................
Electronic Engine Controls (Overview)...............................................................................
General overview................................................................................................................
Powertrain Control Module (PCM)......................................................................................
Knock Sensor.....................................................................................................................
Camshaft Position (CMP) Sensor.......................................................................................
Crankshaft Position (CKP) sensor......................................................................................
Camshaft adjuster solenoid valve.......................................................................................
Manifold absolute pressure and temperature sensor.........................................................
Accelerator pedal position (APP) sensor............................................................................
Throttle control unit.............................................................................................................
Engine Coolant Temperature (ECT) sensor.......................................................................
Ignition coil-on-plug............................................................................................................
Electronic Engine Controls (System Operation and Component Description)...................
System Diagram.................................................................................................................
Speed and TDC recording..............................................................................................
Calculation of the ignition angle......................................................................................
Engine fueling.................................................................................................................
Engine speed control......................................................................................................
Oil monitoring..................................................................................................................
Calculation of valve timing adjustment angle..................................................................
Boost pressure control....................................................................................................
Starting process..............................................................................................................
Alternator control (Smart Charge)...................................................................................
CKP sensor.....................................................................................................................
Broadband HO2S...........................................................................................................
VCT (variable camshaft timing) solenoids......................................................................
MAF sensor.....................................................................................................................
APP sensor.....................................................................................................................
CPP sensor.....................................................................................................................
BPP switches..................................................................................................................
Air conditioning (A/C) pressure sensor...........................................................................
Throttle control unit.........................................................................................................
ECT sensor.....................................................................................................................
Cooling fan module.........................................................................................................
injectors...........................................................................................................................
Ignition coil-on-plug.........................................................................................................
Fuel pressure/fuel temperature sensor...........................................................................
Wastegate control valve..................................................................................................
Engine oil level, temperature and quality sensor............................................................
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303-14-7
303-14-7
303-14-8
303-14-8
303-14-8
303-14-9
303-14-9
303-14-9
303-14-9
303-14-10
303-14-10
303-14-10
303-14-12
303-14-12
303-14-16
303-14-18
303-14-19
303-14-20
303-14-22
303-14-22
303-14-23
303-14-23
303-14-24
303-14-24
303-14-24
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303-14-25
303-14-26
303-14-27
303-14-28
303-14-29
303-14-29
303-14-30
303-14-30
303-14-31
303-14-31
303-14-32
303-14-32
303-14-33
303-14-33
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303-14-2
PAGE 2 OF 2
Exterior aor temperature sensor..................................................................................... 303-14-34

Electronic Engine Controls.................................................................................................
303-14-35
Inspection and Verification.................................................................................................. 303-14-35
Camshaft Position (CMP) Sensor...................................................................
Catalyst Monitor Sensor.................................................................................
Crankshaft Position (CKP) Sensor.................................................................
Heated Oxygen Sensor (HO2S).....................................................................
Knock Sensor (KS).........................................................................................
Mass Air Flow (MAF) Sensor..........................................................................
Powertrain Control Module (PCM).................................................................
Variable Valve Timing (VVT) Oil Control Solenoid..........................................
Brake Pedal Position (BPP) Switch................................................................
Clutch Pedal Position (CPP) Switch...............................................................
(29 232 0)
(29 219 0)
(29 230 0)
(29 220 0)
(29 222 0)
(29 226 0)
(29 200 0)
(29 233 0)
(33 502 0)
(33 503 0)
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303-14-37
303-14-38
303-14-40
303-14-41
303-14-42
303-14-43
303-14-45
303-14-46
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Electronic Engine Controls Component Location
4
3
6
7
8
12
9
10
11
E96941
Item
Description
Throttle control unit
injectors
Comments:
One injector for each cylinder
Fuel pressure/fuel temperature sensor
2008.50 Kuga 8/2011
Item
Description
VVT (variable valve timing) - exhaust

camshaft solenoid
Comments:
One each for the inlet and outlet
camshaft
Ignition coil-on-plug
Comments:
One injection coil for each cylinder
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Item
6
Description
Item
Description
CMP (camshaft position) sensor

Comments:
One each for the inlet and outlet
camshaft
MAF (mass air flow) sensor
10
11
Fan control module
EVAP (evaporative emission) valve
12
CKP (crankshaft position) sensor
MAPT (manifold absolute pressure and

temperature) sensor
3
4
E96950
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Item
Description
Item
Description
Catalyst monitor sensor
MAPT sensor
KS (knock sensor)
Comments:
Two, on 2nd and 4th cylinder
Ambient air temperature sensor
E96980
Item
Description
Item
Description
EVAP valve
HO2S (heated oxygen sensor)
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303-14-6
E96981
Item
Description
FPDM (fuel pump driver module)
Fuel pump
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Electronic Engine Controls Overview

General overview
Engine Management System
Bosch ME 9.0 engine management system
Knock control with two knock sensors
Electronic Throttle Control Unit.
Electronic accelerator pedal
Variable camshaft timing for intake and exhaust
camshafts
Fuel injection supply manifold with combined

fuel pressure and temperature sensor
Sequential multi-port fuel injection
Camshaft position (CMP) sensors for intake and
exhaust camshafts.
satisfies the European exhaust emissions
standard IV
EOBD (European On-board Diagnostic) for the
monitoring of emissions-related components.
Engine power output and engine speed
E62614
Item
Description
Torque
Power output
The engine is controlled by the PCM.

The PCM uses various sensors to calculate the
optimum ignition timing, the optimum injection
quantity and injection time and the position of the
throttle. In addition, various corrections are carried
out, including adjustment of the ignition timing using
the KS and adjustment of the fuel quantity by the
2008.50 Kuga 8/2011
Lambda control. Boost pressure control and fuel

pressure control are also performed by the PCM.
For all work on the engine electronics, it is
essential to ensure that the connectorsare
seated and locked properly.
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E65160
The PCM communicates with all engine sensors

and the other modules. Communication of the PCM
with the other modules and the system diagnostics
takes place via the CAN (controller area network)
data bus.
The following functions are regulated or controlled
by the PCM:
Fuel supply to the engine including lambda
control
Ignition setting including knock control
Idle speed control
Control of optimum valve timing via the camshaft
adjustment for intake and exhaust camshafts
The refrigerant compressor is controlled by the
air conditioning clutch relay and the delivery of
the refrigerant compressor is controlled by a
PWM (pulse width modulation) signal.
Control of EVAP purge valve
Boost pressure control
Control of the cooling fan
Charging system (Smart Charge)
Starting system (Smart Start)
Knock Sensor
E96986
Two KSs are fitted. They are on the cylinder block,

one close to the 2nd cylinder and one close to the
4th cylinder.
When fitting, adhere strictly to the specified
tightening torque, otherwise the KS will not work
properly.
If the signal from one or both KS is implausible or
absent, knock control is deactivated. The PCM
switches to an ignition map that is further away
from the knock limit. As a result, engine damage
caused by combustion knock is avoided. If a fault
occurs, a fault code is stored in the error memory
of the PCM.
Camshaft Position (CMP) Sensor
If the PCM is isolated from the vehicle electrical

system or the battery is disconnected, the throttle
control unit must be initialized.
The PCM is fitted in the engine compartment in the
air filter housing. On right hand drive vehicles a
protective metal plate is also installed to prevent
the plug connector from being pulled off, or make
it harder to pull off, in case of theft. The protective
plate is secured with a shear bolt. The shear bolt
needs to be drilled out in order to remove the
protective plate.
2008.50 Kuga 8/2011
E89993
If one or both CMP sensors fail, a fault is saved in

the error memory of the PCM and the camshaft
adjustment and knock control are deactivated.
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Crankshaft Position (CKP) sensor
Manifold absolute pressure and

temperature sensor
E89994
The CKP sensor can be checked during starting

by measuring the resistance and/or voltage with
the oscilloscope.
The engine cannot work without the CKP signal.
A limp-home mode is therefore not possible. The
engine is switched off or the engine will not start
and a fault is stored in the error memory of the
PCM.
Camshaft adjuster solenoid valve
E96146
During installation of the MAPT sensor, correct

sealing must be ensured to ensure that no
infiltrated air can penetrate into the intake manifold
from outside.
If the MAP (manifold absolute pressure) sensor
fails, the PCM operates with a substitute value.
Accelerator pedal position (APP)

sensor
E96870
For work on the camshaft adjuster solenoids,

extreme cleanliness must be ensured as even
slight impurities can result in failure. The camshaft
adjustment solenoids for the intake and exhaust
camshafts differ only in terms of the position of the
fastening point by which they are fixed to the
cylinder head cover.
If a fault is detected in the camshaft adjustment
solenoids, the solenoids are no longer actuated.
E74146
The APP (accelerator pedal position) sensor

comprises two separate sensors.
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If one of the two APP sensors fails, then only a
proportion of the engine's power will be available
when accelerating. Top speed can nevertheless
be achieved.
If both of the APP sensors fail, the engine is
regulated to a defined speed following a plausibility
check after the BPP (brake pedal position) switch
and brake light switch have been actuated once.
The vehicle can then only be accelerated to a
defined speed.
engine off
Accelerator pedal not pressed
Battery voltage 11 ... 14 V
Ignition key in ON position
Wait approximately 30 seconds until initialization
is complete.
Engine Coolant Temperature (ECT)

sensor
In either case, a fault is saved in the error memory

of the PCM.
1
E94804
The ECT (engine coolant temperature) sensor is

designed as an NTC (negative temperature
coefficient) resistor.
If the signal from the ECT sensor fails, the cooling
fan is on all the time and the A/C (air conditioning)
is turned off. When the ignition is switched on, the
value from the IAT (intake air temperature) sensor
is read. When the engine is running, the
temperature is calculated using a temperature map
stored in the PCM according to how long the
engine has been running. This substitute value is
then used as the basis for calculating the injected
fuel quantity and the ignition timing.
2
E74167
Item
Description
TP (throttle position) sensor
Electric motor
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
After disconnecting the battery or replacing the

throttle control unit or the PCM, initialization is
necessary.
2008.50 Kuga 8/2011
E73540
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The resistance in the ignition coil primary circuit
cannot be checked using a multimeter because
the power output stage is integrated into the ignition
coil.
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G1021907en

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Electronic Engine Controls System Operation and Component

Description
System Diagram
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G1021908en

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Inputs
17
9
24
10
18
11
19
12
20
13
21
14
15
22
16
23
E96882
2008.50 Kuga 8/2011
G1021908en

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Item
Description
Item
Description
Medium speed CAN data bus (MS-CAN)
13
Broadband HO2S
25)

Comments:
Serves as a gateway between the two
CAN databus systems.
14
15
Air conditioning (A/C) pressure sensor

30)
16
KS
8)
17
APP sensor
28)
18
MAPT sensor
9)
19

33)
20
Exterior aor temperature sensor

34)
21
Engine oil level, temperature and quality

sensor
34)
22
Ignition switch
23
Battery
24
PCM
8)
High speed CAN data bus (HS-CAN)
CPP (clutch pedal position) sensor

29)
BPP switches
29)
MAF sensor
27)
TP sensor
Refer to Component Description: Throttle
control unit (page 33)
Comments:
It is incorporated into the throttle control
unit
ECT sensor
31)
10
CKP sensor
24)
11
CMP sensor - intake camshaft

8)
12
CMP sensor - exhaust camshaft

8)
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Output signals
4
14
15
16
6
17
8
18
7
9
19
10
20
11
13
12
21
22
E96883
2008.50 Kuga 8/2011
G1021908en

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303-14-16

Item
Description
Item
Medium speed CAN data bus (MS-CAN)
15
DLC
GEM
Comments:
Serves as a gateway between the two
CAN databus systems.
High speed CAN data bus (HS-CAN)
PCM
8)
LIN (local interconnect network) databus
Alternator
Heating element - broadband HO2S
Catalyst monitor sensor heating element
10
Powertrain Control Module relay
11
Starter Relay
12
FPDM
Comments:
Description
Air conditioning clutch relay
Comments:
Refer to: Climate Control (412-01
Climate Control, Description and
Operation).
16
EVAP valve
Comments:
17
VCT oil control solenoid, exhaust camshaft

solenoids (page 26)
18
VCT oil control solenoid, intake camshaft

solenoids (page 26)
19
Cooling fan module

Comments:
Refer to: Engine Cooling - 2.5L Duratec
(147kW/200PS) - VI5 (303-03 Engine
Cooling, Description and Operation).
20

Comments:
Refer to: Turbocharger (303-04 Fuel
Charging and Controls - Turbocharger
Refer to: Fuel Tank and Lines - 2.5L

Duratec (147kW/200PS) - VI5 (310-01
Fuel Tank and Lines, Description and
Operation).
13
Fuel pump
21
14
injectors
?)
Comments:
5x
10)
Comments:
5x
22

30)
Comments:
Actuator motor unit
System Operation
The engine is controlled by the PCM. For this
purpose, the PCM uses information from the
sensors, sender units and switches. In addition,
the PCM receives information from other control
modules via the CAN data bus. All the information
is processed in the PCM and is used to control or
regulate the different actuators.
These are:
the throttle control unit,
the fuel injectors,
2008.50 Kuga 8/2011
the camshaft adjustment,

the boost control solenoid valve
and the ignition coils.
Some values are sent via the CAN databus to other
systems.
The following functions are regulated or controlled
by the PCM:
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Starting process
Engine running
Fuel supply to the engine including lambda
control
Ignition setting including knock control
Idle speed control
Valve timing via the camshaft adjuster for the
intake and exhaust camshafts (including
internal exhaust gas recirculation)
Refrigerant compressor (activation, deactivation
and delivery)
EVAP purge valve
Charging system
Fuel is supplied to the engine via a sequential
multi-point injection system. Ignition is performed
by a distributor-less ignition system with one
ignition coil unit for each cylinder.
The PCM optimizes engine power and emissions
at all times by processing the sensor signals and
information received via the CAN databus and
using these for open or closed loop control of the
different variables.
The PCM contains part of the PATS (passive
anti-theft system).
The PCM is supplied with battery voltage via a fuse
in the BJB (battery junction box). This power supply
is needed to ensure that saved data is not lost
when the engine is switched off.
For other power supply requirements, the PCM
switches on a relay in the BJB which is responsible
for supplying power to the PCM and to some
sensors and actuators. Each of these are protected
by fuses in the BJB.
To guarantee optimum engine running at all times,
the PCM has several adaptive (self-learning)
functions. These adapt the output signals to
changing circumstances, such as wear or system
faults.
In some cases a faulty signal is replaced with a
substitute value or limited. A substitute value can
be calculated from other signals or it can be
predefined by the PCM. The substitute value allows
the vehicle to keep on running without the emission
values changing unduly. Depending on the signal
failure, the PCM operates in emergency mode. In
this mode, the engine power and/or the engine
speed is reduced to prevent further damage.
Depending on the faulty signal, a fault code is
stored in the error memory of the PCM. These can
2008.50 Kuga 8/2011
be read out using IDS (Integrated Diagnostic

System) via the DLC.
The PCM processes and evaluates the signals
from the sensors. The following sensors send
signals to the PCM:
CMP sensors
CKP sensor
MAF sensor
KS
ECT sensor
TP sensor
APP sensor
Broadband HO2S
MAPT sensor
Alternator
Fuel temperature and fuel pressure sensor
Engine oil level, temperature and quality sensor
Outside air temperature sensor
The following components receive signals from the

PCM:
Powertrain Control Module relay

A/C clutch relay
injectors
Direct ignition coils
Cooling fan module
Camshaft adjuster solenoid valve
Starter Relay
EVAP purge valve
Alternator
Heating element - broadband HO2S
Catalyst monitor sensor heating element
FPDM
Air conditioning compressor
The PCM receives the following signals via the

CAN databus:
APP
CPP
BPP
Vehicle speed.
Refrigerant compressor request
PATS
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Torque reduction request (stability assist
module)
Cruise control request
The PCM sends the following signals via the CAN
databus:
Fuel pump relay on/off
Engine speed
Warning lights on/off (MIL (malfunction indicator
lamp), battery warning lamp)
PATS
ECT
Air conditioning pressure transducer
Outside air temperature
With the aid of the input and output signals listed
above, the PCM controls / regulates engine
starting, fuel injection and fuel pressure, ignition,
boost pressure, camshaft adjustment, tank purging,
the radiator fan and the refrigerant compressor.
An additional sensor wheel for the CKP sensor is

located on the flywheel. This has 60-2 teeth. The
gaps between the teeth are required for detection
of TDC. The CKP sensor works according to the
induction principle and generates a sinusoidal
signal voltage whose level and frequency are
speed-dependent.
From the frequency of the signal the PCM
calculates the engine speed. Each time the engine
rotates, the double gap in the sensor wheel alters
the sinusoidal oscillation that is generated; this
helps the PCM to detect the TDC position of
cylinder 1.
The signal from the CKP sensor is used to
determine
the crankshaft position,

the engine speed,
the ignition timing,
the injection timing and
the adjustment angle of the VVT units.
Speed and TDC recording

The CKP uses the PCM sensor to record engine
speed and detect 1st cylinder TDC (top dead
center).
5
2
3
E96631
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Item
Description
CKP sensor
Tooth pitch
Flywheel ring gear
Reference mark
Voltage (sinusoidal-like signal curve)
The acceleration of the flywheel at each power

stroke results in a change in the CKP signal.
During the power stroke, the combustion pressure
acting on the piston causes an acceleration of the
crankshaft and thus also of the flywheel. This is
apparent in the voltage curve from slightly higher
frequencies and amplitudes of the CKP signal.
Item
Description
60-2 pulses per revolution of the

crankshaft
Tooth center
Reference mark
Tooth pitch
The PCM calculates engine load using the MAF

sensor signal, the throttle position and engine
speed. This is done using ignition maps that are
stored in the PCM. The ignition timing is adjusted
according to the operating condition of the engine,
for cold starting for example.
Ignition map
Calculation of the ignition angle

Since propagation of the flame front in the air/fuel
mixture always takes the same amount of time, the
ignition of the air/fuel mixture has to take place
earlier or later depending on the engine speed.
The higher the speed, the earlier ignition must
occur. This ensures that maximum combustion
pressure is achieved immediately after Top Dead
Center and that maximum combustion pressure
acts on the piston.
When starting the engine, ignition timing is
determined by the CMP purely from the ignition
map and information on camshaft position (CKP
sensors) and crankshaft position (PCM sensor).
As soon as the engine is running, the following
data are used as a basis for calculating the ignition
angle:
the engine speed,

the engine load,
the coolant temperature and
the KS signal.
The ignition angle has a major impact on engine

operation. It affects
engine performance
exhaust emissions
fuel consumption,
combustion knock behavior and
engine temperature.
The higher the engine load, i.e. the torque demand,

the richer the air/fuel mixture, the longer the
combustion period and the earlier the ignition.
2008.50 Kuga 8/2011
E96319
Item
Description
Engine load.
Engine speed
Ignition angle
The ignition maps were calculated in a series of

tests. Particular attention is paid to the emission
behaviour, power and fuel consumption of the
engine. The ignition map is stored in the data
memory of the PCM.
By adjusting the ignition timing it is also possible
to influence the engine speed to some extent
without having to change the throttle valve position.
This has advantages for idling stabilization, as the
engine speed and hence the engine torque respond
far more quickly to a change in the ignition timing
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than to a change in the throttle valve position. The
ignition timing also changes much more quickly.
(CMP sensors) and crankshaft position (CKP

sensor) information.
To keep the ignition point as close as possible to

the knock limit and so optimize the efficiency of the
engine, two KS are installed in the engine, which
pick up the mechanical vibrations of the engine
and convert them into an electrical signal for the
PCM.
If the PCM detects combustion knock, the ignition

timing for the cylinder in question is gradually
retarded for a few crankshaft revolutions until
combustion knock stops. After that the ignition point
is slowly returned to the calculated value. This
facilitates individual cylinder ignition, which makes
it possible for the engine to operate at optimum
efficiency at the knock limit.
Engine fueling
Fuel is supplied by a non-return fuel system.
Fuel pressure and fuel delivery rate are regulated

by the PCM with the aid of the FPDM. The fuel
pump is supplied with a cycled voltage by the
FPDM. By cycling the voltage, the fuel pump output
can be steplessly adjusted. The fuel pressure can
be steplessly regulated between 3 and 5 bar.
Adjusting the fuel pump output has the following

advantages:
The fuel pump's power consumption is reduced,
thereby reducing the load on the vehicle's power
supply system.
The fuel pump's service life is increased.
Fuel pump noise is reduced.
Fuel pressure regulator

2
TIE42093
Item
Description
Normal combustion
Knocking combustion
Pressure characteristic in cylinder
Output signal from KS
The term "knocking" is used to describe

combustion processes in which the flame front
propagation speed reaches the speed of sound.
This can happen towards the end of combustion
in particular, when unburnt air/fuel mixture on the
combustion chamber walls self-ignites due to the
increase in pressure following initiation of regular
combustion. The resulting pressure peaks damage
the pistons, cylinder head gasket and cylinder
head.
The cylinder in which combustion knock is
occurring is identified from the camshaft position
2008.50 Kuga 8/2011
The PCM calculates the required fuel pressure

based on the operating conditions. The PCM
transmits a corresponding PWM signal to the
FPDM. With the aid of this signal, the FPDM
actuates the pump by sending, in turn, a PWM
signal to the ground connection of the fuel pump.
The fuel pump can be steplessly regulated by
varying the pulse width of the PWM signal.
The PCM continuously monitors the fuel pressure
in the fuel rail by means of the fuel temperature/fuel
pressure sensor. If the pressure deviates from the
calculated value, the PCM adapts the PWM signal
to the FPDM accordingly. Thus the fuel pressure
levels out at approx. 4 bar.
For safety reasons, the PCM switches off fuel
delivery if the SRS (supplemental restraint system)
module detects a crash.
Regulation of injected fuel quantity
The electromagnetically controlled injectors dose
and atomize the fuel. The quantity of injected fuel
is regulated by the duration of actuation of the fuel
injectors. The fuel injectors are either closed (not
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actuated) or opened (actuated). Each cylinder has
its own injector. The injection is accurately dosed
and takes place at a time determined by the PCM.
Injection takes place immediately in front of the
intake valves of the cylinder. The injectors are
actuated ground side via end-stages integrated
into the PCM and using the signal calculated by
the engine management system. Power is supplied
via the Powertrain Control Module relay in the BJB.
The injected fuel quantity depends on the opening
time, the fuel pressure and the diameter of the
nozzle holes.
The fuel metering is determined via open or
closed-loop control.
The open control loop differs from the closed
control loop in that the lambda control is
deactivated.
The PCM switches from closed to open-loop control
if the HO2S cools down to below 600C or fails, as
well as when accelerating, coasting and at full load.
Regulation of injected fuel quantity via the PCM
involves:
controlling the fuel pump,
calculating the required quantity of fuel for
engine starting,
observance of the desired air/fuel ratio,
calculating air mass,
and calculating the fuel quantity for the different
operating states and corresponding fuel
adjustment measures.
(three-way catalytic converter) and economical fuel

consumption. With closed loop control, the signals
from the HO2S are analyzed by the PCM and the
engine always runs in the optimum range of = 1.
In addition to the normal HO2S, the signal from the
monitoring sensor for the catalytic converter is also
included in the control. The lambda control is
optimized on the basis of this data.
Certain factors such as wear, component
tolerances or more minor defects such as air leaks
in the intake system are compensated for by
lambda control. If the deviation occurs for a longer
period of time, this is recorded by the adaptive
(self-learning) function of lambda control. In this
instance, the entire map is shifted by the
corresponding amount, to enable control to
commence once again from the virtual baseline.
These adaptive settings are stored in the PCM and
are also used in open-loop control conditions.
If the adaptive value is too high or too low, an error
is stored in the fault memory of the PCM.
Oxygen sensor (HO2S) and catalyst monitor
sensor
A broadband HO2S is used as the HO2S. The
HO2S is located in front of the TWC. The catalyst
monitor sensor is located in the center of the TWC
so that it can detect any deterioration in the
cleaning performance of the TWC more quickly.
The HO2S measures the residual amount of
oxygen in the exhaust before the TWC.
Open loop control
The catalyst monitor sensor measures the amount

of oxygen in the exhaust gas after or in the TWC.
Open loop control is used primarily for fuel

injection, as long as the signals of the HO2S are
not involved in the calculation of the PCM.
Both the HO2S and the catalyst monitor sensor

transmit these data to the PCM.
The two most important reasons that make it

absolutely essential to run the engine without
lambda control (open-loop control) are the following
operating conditions:
Cold engine (starting, warm-up phase)
Full-load operation (WOT (wide open throttle))
Under these operating conditions the engine needs
a rich air/fuel mixture with lambda values below
= 1 in order to achieve optimum running or
optimum performance.
It is possible to keep this unregulated range very
small by using a broadband HO2S.
Closed-loop control
Closed loop control ensures strict control of
exhaust emissions in conjunction with the TWC
2008.50 Kuga 8/2011
The broadband HO2S works at temperatures of

between 650C and 900 C. If the temperature
rises above 1000C, the oxygen sensor will be
irreparably damaged.
To reach optimum operating temperature as quickly
as possible, an electrically-heated oxygen sensor
is installed. The heating also serves to maintain a
suitable operating temperature while coasting, for
example, when no hot gases are flowing past the
oxygen sensor.
The heating element in the HO2S is a PTC
(positive temperature coefficient) resistor. The
heating element is supplied with battery voltage as
soon as the Powertrain Control Module relay
engages. The HO2S is earthed via the PCM. As
the heating current is high when the element is
cold, it is limited via PWM in the PCM until a certain
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current value is reached. The PCM then
permanently connects the heating element to earth.
The catalyst monitor sensor is used by the PCM
to measure the oxygen content in the exhaust gas
in the TWC. If all the conditions for catalyst
diagnostics are met, based on this information the
PCM can check that the TWC is working
satisfactorily. The information is also used to
improve the air/fuel mixture adjustment.
The catalyst monitor sensor is similar in function
to an HO2S. The signal transmitted by the catalyst
monitor sensor changes sharply if the oxygen
content in the exhaust gas changes. For this
reason, catalyst monitor sensors are also called
"jump lambda sensors".
Fuel tank purging
The EVAP purge valve is only actuated by the PCM
if the coolant temperature is at least 60C.
Actuation is done ground side by means of a PWM
signal. This makes it possible to have the full range
of opening widths, from fully closed to fully open.
The PCM determines from the operating conditions
when and how wide to open the EVAP tank purge
valve. If the EVAP purge valve is opened, the
engine sucks in ambient air through the activated
charcoal in the evaporative emission canister as
a result of the vacuum in the intake manifold. In
this way the adsorbed hydrocarbons are led to the
combustion chamber of the engine.
allows the operation of the potentiometers to be

checked. The signal from the TP sensor is
amplified in the lower range (idle to a quarter open)
by the PCM to enable more precise control of the
throttle in this range. This is necessary because
the engine is very sensitive to changes in throttle
angle in this throttle opening range.
With the throttle valve position kept constant, the
ignition angle and the injected fuel quantity are
then varied to meet the torque demands.
Depending on the operating state of the engine, a
change in the position of the throttle flap may not
be necessary when the APP sensor changes.
If a fault develops in the throttle control unit, a
standby function is executed. This standby function
allows a slight opening of the throttle flap, so that
enough air passes through to allow limited engine
operation. For this purpose, there is a throttle flap
adjustment screw on the throttle housing. The
return spring closes the throttle flap until the stop
of the toothed segment touches the stop screw. In
this way a defined throttle flap gap is formed for
limp home mode.
The stop screw has a spring loaded pin, which
holds the throttle flap open for limp home mode.
In normal operating mode, this spring loaded pin
is pushed in by the force of the electric motor when
the throttle flap must be closed past the limp home
position (e.g. for idle speed control or overrun
shutoff).
The EVAP tank purge valve is not actuated and

system cleaning is interrupted if the engine
switches to idle and/or a closed-loop control
process is initiated.
Oil monitoring
Power (battery voltage) is supplied via the

Powertrain Control Module relay in the BJB. The
solenoid coil resistance is between 17 and 24 ohms
at 20C.
Calculating the engine oil level
Engine speed control

The APP sensor provides the PCM with information
about the driver's request for acceleration.
The throttle control unit receives a corresponding
input signal from the PCM. An electric motor then
moves the throttle valve shaft by means of a set
of gears. The position of the throttle is continuously
recorded by the TP sensor. Information on throttle
position is processed and monitored by the PCM.
The TP sensor comprises two potentiometers.
These work in opposite ways to each other. In one
potentiometer, the resistance increases when the
throttle is opened, in the other it decreases. This
2008.50 Kuga 8/2011
The engine does not have an oil pressure

switch. The oil level and oil quality are calculated.
The oil level is determined by continuous
measurement of the capacitance (i.e. the ability to
store an electrical charge) between the two
capacitive elements of the engine oil
level/temperature/quality sensor. The different oil
levels cause the capacitance between the elements
to change. The data are recorded by the PCM and
converted into an oil level value. Temporary
fluctuations in oil level are automatically filtered out
by the PCM.
Calculating oil quality
The PCM calculates the oil quality from the oil level
measurement and the oil temperature measured
by the sensor, plus the engine speed and the
average fuel consumption. The driver is informed
about when an oil change is due.
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Calculation of valve timing adjustment
angle
The 2.5L Duratec (VI5) engine has two camshaft
adjustment units which work independently of each
other.
One camshaft adjustment solenoid is installed for
each intake camshaft and exhaust camshaft.
This allows the PCM to continuously adjust the
intake and exhaust-side camshaft adjustments
independently of one another. The timing is
adjusted by the PCM using curves; adjustment is
primarily done as a function of engine load and
engine speed.
In this way the engine performance is increased
and internal exhaust gas recirculation is realized.
The advantages of camshaft adjustment are as
follows:
Higher torque and improved torque
characteristics
Reduced fuel consumption
Improved emissions performance
The camshaft adjustment solenoids are actuated
by the PWM by means of a PCM signal.
Continuous adjustment of the camshafts by the
PCM is achieved by means of the camshaft
adjustment solenoids, the camshaft adjustment
units and two CMP sensors. A defined quantity of
engine is oil is supplied to or drained from the
adjustment units via the camshaft adjustment
solenoids. The existing EOP (engine oil pressure)
is taken into account in the process. In this way
the valve timings are adjusted according to the
operating condition of the engine. The camshaft
adjusters work according to the vane-cell principle.
On starting the engine, both camshafts are
mechanically locked in their starting positions. The
intake camshaft is in the maximum late position
and the exhaust camshaft in the maximum early
position.
Control is divided into four main areas:
Low engine speed and low load

Partial load
Low engine speed and high load
High engine speed and high load
At low engine speed and low load, the exhaust

valves open early and the intake valves open late.
The result is reduced fuel consumption and more
uniform idling.
2008.50 Kuga 8/2011
In the partial load range, the exhaust valves and

the intake valves open late. The late opening of
the exhaust valves results in a good utilization of
the expanding gases in the cylinder. Closing the
exhaust valves after Top Dead Center allows
internal exhaust gas recirculation through aspiration
of exhaust gases into the combustion chamber.
Moreover, the intake valves close after Bottom
Dead Centre, allowing the fresh air/fuel mixture
and exhaust gases to flow back into the intake
tract. The result is reduced fuel consumption and
low emissions.
At low engine speed and high engine load, the
exhaust valves open late and the intake valves
open early. Due to the resulting valve opening
overlap at Top Dead Centre, the pulsating gas
column within the combustion chamber is utilized
to achieve better charging of the combustion
chamber. The result is increased torque at lower
RPM.
At high engine speeds and high engine load, the
exhaust valves open early and the intake valves
close late. Because a rapid gas exchange must be
achieved at high engine speeds, the early opening
of the exhaust valves achieves better expulsion of
the exhaust gas and the late closing of the intake
valves improves cylinder charge efficiency.
Optimum power output is achieved.
Many other camshaft positions are possible in
addition to these settings.
In order to avoid a malfunction in the camshaft
adjustment units at excessively low ambient or
engine-oil temperatures, they are activated by the
PCM with a time delay via the camshaft adjustment
solenoids. The PCM receives the information
required for this from the ECT sensor and the
outside air temperature sensor.
When idling and during deceleration, the camshaft
adjustment solenoids are activated repeatedly by
the PCM in order to remove any dirt which may be
on the bore holes and ring grooves.

Optimum regulation is achieved by means of an
electronically-controlled solenoid valve, the boost
control solenoid valve.
Refer to: Turbocharger (303-04 Fuel Charging and
Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5, Description and
Operation).
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Starting process
CMP
The PCM enables the starting process when a key

providing a valid code is read via the PATS.
Refer to: Starting System (303-06 Starting System
- 2.5L Duratec (147kW/200PS) - VI5, Description
and Operation).
Alternator control (Smart Charge)

The vehicle is fitted with a Smart Charging charge
system.
In this system, the charge voltage is regulated by
the PCM.
Refer to: Generator (414-02 Generator and
Regulator, Description and Operation).
PCM
E89993
The intake and exhaust camshafts each have a

sensor installed on them.
The CMP sensor is realized as a Hall effect sensor
and is provided by the PCM with a 5 volt supply.
The Hall effect sensor emits a signal when the
pulse segments incorporated into the sensor wheel
rotate past the tip of the sensor. If an increase
occurs in the area of the sensor, the PCM receives
a 'high' signal with a maximum voltage of 4.5V. If
a gap occurs in the area of the sensor, a 'low'
signal is sent to the PCM. Here the voltage is
approx. 0.5V.
CKP sensor
E73522
A voltage transformer integrated into the PCM

provides various components of the PCM and
sensors on the engine with a 5 volt supply.
Functions which work at battery voltage, such as
the injectors, are controlled via internal power end
stages or, like the ignition coils, via external power
end stages in the ignition coils themselves.
2008.50 Kuga 8/2011
E89994
The CKP sensor utilizes the induction principle. A

sinusoidal voltage is sent to the PCM. When
performing a voltage test, ensure that the CKP
sensor is connected to the engine wiring harness
This is necessary, otherwise the sensor will not be
subjected to any load and incorrect measurements
will result.
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KS
2
5
E96327
Item
Description
Seismic mass
Piezoceramic
Housing
Piezoceramic contact
The KS converts mechanical vibrations of the

cylinder block into electrical pulses which can then
be processed by the PCM.
The KS consists of piezo-ceramic crystals that
generate a voltage when subjected to a mechanical
load.
When fastening the KS, make sure the specified
torque is adhered to. In this way a defined initial
tension is applied to the crystals which exerts an
influence on the operation of the KS.
When the engine is running, the pressure
fluctuations arising due to the combustion process
cause vibrations in the cylinder block. These act
on the crystals in the KS, causing the sensors to
produce an output signal. The stronger the
vibrations, the higher the frequency and the AC
voltage. These signals are evaluated by the PCM
and compared with stored data.
2
TIE42093
Item
Description
Normal combustion
Knocking combustion
Pressure characteristic in cylinder
Output signal from KS
Broadband HO2S
TIE42061
The planar broadband HO2S also allows

measurements of the exhaust gas which deviates
from the stoichiometric ratio (lambda = 1). The
measuring range extends from lambda 0.7 to 2.8,
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whereby the broadband HO2S emits a clear,
constant signal.
The broadband HO2S consists of a Nernst

concentration cell and an oxygen pump cell, which
transports the oxygen ions.
1
3
4
2
TIE42062
Item
5
7
TIE42098
Item
Description
Nernst concentration cell
Oxygen pump cell
Measuring area
Pump current
Regulating switch
Reference voltage
Heater
Heating voltage
Reference air duct
Between the oxygen pump cell and the Nernst

measuring electrode, there is a diffusion gap which
acts as the measuring area and is connected to
the exhaust gas. The Nernst concentration cell is
connected via a duct with the ambient reference
air and the measuring area. It detects the mixture
composition in the measuring area. A concentration
of lambda = 1 is set in the measuring area using
the oxygen ion flow. This is done by applying a
reference voltage which results in a pump current.
Description
Ip
Pump current in mA
positive pump current
negative pump current
The pump current represents a direct measurement

of the mixture composition. With lambda 1 (14.7
kg air/1 kg fuel), the pump current is 0 mA. The
relatively small measured current is converted into
a voltage signal in the PCM using an evaluation
circuit. The heating of the broadband HO2S is
supplied with a reference voltage of 11 to 14V. The
operating temperature of the broadband HO2S is
650 - 900 C.
The characteristic curve of the broadband HO2S
is constant (linear), without a lambda jump.
VCT (variable camshaft timing) solenoids

The camshaft adjustment solenoids are multi-way
solenoid valves that are actuated with a PWM
signal, thereby allowing the valve plungers to be
steplessly adjusted.
When the exhaust gas is lean, the oxygen pump

cell is actuated in such a way that oxygen ions are
pumped out of the measuring area. This is detected
by the regulating switch, so that the flow can move
(positive direction).
If the exhaust gas is rich, then the current direction
is reversed, i.e. the cell pumps oxygen ions into
the measuring area. The regulating switch detects
this, so the flow is reversed (negative direction).
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MAF sensor
1
1
5
6
7
8
E96872
Item
Description
Solenoid coil
Engine oil pressure supply bore and ring

groove for camshaft adjustment unit
chamber A
E58185
Item
Description
Housing
Housing cover
Control electronics
Tappet
Sensor element
Engine oil pressure supply bore for

camshaft adjustment solenoid
Sensor measuring cell
Heating zone
Engine oil pressure supply bore and ring

groove for camshaft adjustment unit
chamber B
Spring
Engine oil return bore
The MAF sensor works on the hot-film principle.

The MAF sensor is powered via the Powertrain
Control Module relay in the BJB. The MAF sensor
is connected to ground via the PCM.
The MAF sensor sits in a molded part which
protrudes into the center of the air cleaner's outlet
pipe. From this position, it measures the air mass
drawn in by the engine.
The air mass aspirated by the engine is determined
on the basis of the cooling effect of the intake air
via a hot-film element in the MAF sensor. The
greater the aspirated air mass, the greater the
cooling effect and the lower the electrical resistance
of the hot-film element. The electronics in the MAF
sensor process this resistance value and send a
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MAPT
voltage signal to the PCM corresponding to the

aspirated air mass.
This analogue voltage signal is between 0.5V and
5V. Low mass of intake air produces a low voltage
signal. A high mass of intake air produces a
correspondingly high voltage signal.
The MAF sensor is also capable of detecting the
backflow of the intake air. A sensor element is
heated electrically on the integrated chip and then
cooled by the air flowing through. The regulating
switch supplies the heating current in such a way
that it attains a constant excess temperature in
comparison to the intake air. The mass air flow and
the direction of flow can be derived from this
heating current (given in the form of a signal
voltage). Below a certain voltage value there is a
return flow. The direction is flow is registered by
two sensors pointing in different directions. The
measurement does not require a great deal of
software processing effort, even with a strongly
pulsating mass air flow.
E96146
The MAPT sensor combines two sensors in one

housing. These are the MAP sensor and the IAT
sensor. They take the form of a piezoelectric
resistor and an NTC resistor.
The MAP sensor receives a reference voltage of
5V from the PCM. The output signal from the MAP
sensor element is an analog voltage signal which
changes proportionately to the prevailing pressure
in the intake manifold.
The IAT sensor records the temperature of the
intake air downstream of the intercooler.
APP sensor
1
2
0
5
6
7
E96668
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Item
Description
Item
Description
Amperes
Analog alternating current
Volts
Generated PWM signal.
Valve rotor
Electronics
Primary coil
PCM
Comments:
PWM signal is converted in the GEM
and forwarded via the CAN data bus.
Secondary coil
The APP sensor is a double contactless inductive

sensor. The APP sensor is integrated with the
accelerator pedal in the accelerator pedal module.
The inductive sensor essentially works in a similar
way to a transformer. The incoming DC voltage
first has to be converted into AC voltage.
Depressing the accelerator pedal moves a rotor.
This induces the AC voltage from the primary coil
into the secondary coil. The strength of the
induction depends on the position of the rotor:
The sensor works on the Hall-effect principle and

records the position of the piston in the master
cylinder without contact. The permanent magnet
required for recording the position is located in the
piston of the clutch master cylinder.
The signal from the CPP sensor is recorded by the
GEM and transmitted to the CAN via the PCM bus.
BPP switches
no accelerator-pedal actuation: low induction,

i.e. low amplitude of the AC voltage,
full accelerator-pedal actuation: high induction,
i.e., high amplitude of the AC voltage.
To allow the PCM to process the AC voltage signal
output by the secondary coil, the signal must first
be converted into a PWM signal in the sensor
electronics.
In the APP sensor the signals are split as follows:
APP 1 = PWM signal to the GEM and from there
via the CAN data bus to the PCM.
APP 2 = the analogue DC (direct current) signal
is sent directly to the PCM.
Both signals are monitored by the PCM for
plausibility.
E94800
The BPP switch is designed as normally-closed

contact. In its rest state the switch is closed and
sends an earth signal to the GEM.
The brake light switch is designed as
normally-open contact and is open in its rest state.
CPP sensor
E70695
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E74157
The A/C pressure sensor is installed on the

high-pressure side of the A/C. The input voltage is
5V, the output voltage is between 0.5V and 4.5V
depending on the cryogenic fluid pressure. When
the cryogenic fluid pressure is low, the output
voltage is also low.
Pressure (bar)
Voltage (Volts)
Approx. 30
3.9 - 4.0
Approx. 25
3.3 - 3.4
Approx. 20
2.7 - 2.8
Approx. 15
2.1 - 2.2
Approx. 10
1.6 - 1.7
Approx. 5
1.0 - 1.1
Approx. 1
0.5 - 0.7
2008.50 Kuga 8/2011
E74167
Item
Description
TP sensor
Electric motor
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ECT sensor
E94804
The ECT sensor is designed as an NTC resistor.

A voltage of 5V is applied to the ECT sensor by
the PCM. The PCM is able to determine the coolant
temperature from the temperature-dependent
voltage drop at the sensor.
Cooling fan module

E74168
Item
Description
Stop screw
Toothed segment
Throttle flap spindle
Throttle flap return spring
Joint shaft
Electric motor with pinion
E94806
CAUTION: The throttle control unit must

not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
The cooling fan module is directly supplied with

battery power via a 60A fuse in the BJB. The
radiator fan speed is controlled by the PWM via a
PCM signal.
If there is a fault, the throttle is returned to its

original position by means of the throttle valve
return spring. In this position, the throttle valve is
still slightly open. As a result, a higher idle speed
is set, enabling the vehicle to be driven, though
within narrow limits.
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injectors
Item
1
Electrical connector
Seal
Fuel inlet with fine sieve
Housing
Coil
Spring
Valve needle with solenoid armature
Valve seat with nozzle hole disk
2
1
Description
5
6
The fuel injectors consist of a housing with fuel

passages, a coil and an injector needle with a
solenoid armature. The fuel inlet in the injector
features a fine sieve. There are two holes in the
nozzle hole disk. These are arranged so that two
jets of fuel emerge. Each jet supplies one intake
valve of the respective cylinder.
2
E96472
4
1
5
2
7
E73516
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Item
Description
Item
Description
Coil-on-plug ignition coil
Primary winding
Spark plug connector
Secondary winding
Low-voltage connection
Spark plug
Laminated soft-iron core
High-voltage connection via spring contact
In an ignition system with coil-on-plug ignition coils,

each cylinder is actuated individually and only once
per cycle (working stroke). The coil-on-plug ignition
coils are mounted directly on the spark plugs,
therefore no ignition cables are required between
the ignition coils and the spark plugs.
Each individual ignition coil is actuated on the
low-voltage side by the PCM. The power
end-stages are incorporated into the coil-on-plug
ignition coils. Only the actuating current for these
power end-stages is controlled by the PCM.
Temperature
Resistor
0 C
5896 Ohm
10 C
3792 Ohm
20 C
2500 Ohm
30 C
1707 Ohm
40 C
1175 Ohm
The values of the fuel pressure/fuel temperature

sensor can be read out with IDS. The displayed
values are absolute values (fuel pressure +
atmospheric pressure).
E73531
The fuel pressure/fuel temperature sensor is a

combination of two sensors, one for the fuel
absolute pressure and one for the fuel temperature.
The sensors register the fuel values in the fuel
injection supply manifold. The sensor is supplied
with a 5V voltage by the PCM.
The fuel pressure sensor is a piezoresistor and
works using an analog signal. The change in output
voltage mirrors the change in pressure in the fuel
rail. If the pressure is low, the output voltage is also
low.
E73539
The boost control solenoid valve is a 2/3-way valve

that is actuated with a PWM signal. This allows the
valve opening to be steplessly adjusted.
Power (battery voltage) is supplied via the
Powertrain Control Module relay in the BJB. The
solenoid coil resistance is around 23 ohms at 20
C.
The fuel temperature sensor is an NTC resistor.

When the fuel pressure/fuel temperature sensor is
disconnected, the resistance of the fuel
temperature sensor between connections 1 and 2
of the sensor can be measured.
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Engine oil level, temperature and quality
sensor
E95312
The sensor is a combined oil level and oil

temperature sensor.
The sensor consists of:
Electrical connector
Integral electronics
PTC resistor
Capacitive element consisting of two tubes with
a space between them. The one tube represents
the positive side, the other the negative. The oil
between the tubes creates the capacitive
properties.
The sensor receives a 5V voltage from the PCM.

The sensor generates a PWM signal that is sent
to the PCM.
Exterior aor temperature sensor

The outside air temperature sensor is a NTC
resistor and is supplied with a 5V voltage by the
PCM.
The resistance of, and consequently the voltage
from, the outside air temperature sensor changes
as a function of temperature.
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Electronic Engine Controls

General Equipment

Electrical
Fuse(s)
Wiring harness
Relay(s)
Sensor(s)
Switch(es)

equipment to diagnose the system.
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Camshaft Position (CMP) Sensor(29 232 0)

4. Torque: 10 Nm
Removal
x6

2.

residue.
E65073
5. Torque: 10 Nm
E65070
3.

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
E67947
Installation
3
1
2
E68504
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Catalyst Monitor Sensor(29 219 0)

Removal
2.
E67411
3. Torque: 47 Nm
E66051
Installation
2008.50 Kuga 8/2011
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Crankshaft Position (CKP) Sensor(29 230 0)

Removal

Installation).
5.

residue.

2.
x7
E65070
E86012
6.
3. Turn the engine to top dead center (TDC).

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
3
1
E71093
2
E68504
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7. Torque: 10 Nm
E65747
Installation
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Heated Oxygen Sensor (HO2S)(29 220 0)

5. Torque: 45 Nm
Removal
1.

residue.
E66305
Installation
E65070
2.
1
E67948

4.
x7
E86012
2008.50 Kuga 8/2011
G965266en

TO MODEL INDEX
303-14-41
303-14-41
Knock Sensor (KS)(29 222 0)

Removal
Installation).
2. NOTE: Make sure that the sensor is installed in
the same location as when removed.
Torque: 20 Nm
E65542
Installation
2008.50 Kuga 8/2011
G965267en

TO MODEL INDEX
303-14-42
303-14-42
Mass Air Flow (MAF) Sensor(29 226 0)

Removal
1. Torque: 10 Nm
x2
E106250
Installation
2008.50 Kuga 8/2011
G1079138en

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303-14-43
303-14-43
Powertrain Control Module (PCM)(29 200 0)

General Equipment
3.5 mm Drill Bit
4.
Center Punch
Removal
Download the PCM and throttle body
configuration information into the diagnostic tool,
using the Programmable Modules Installation
routine.
E93509
5.


3.
E65856
6. Torque: 7 Nm
E63329
E66285

Installation).
8. 1. General Equipment: Center Punch
2. General Equipment: 3.5 mm Drill Bit
2008.50 Kuga 8/2011
G1079137en

TO MODEL INDEX
303-14-44
303-14-44
x2
4
3
E92348
9.

2. Tighten the shear bolt until the shear bolt head
is sheared off.
E65361
Installation
E92350
All vehicles
Upload the PCM and throttle body configuration
information into the PCM, using the
Programmable Modules Installation routine.
2008.50 Kuga 8/2011
G1079137en

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303-14-45
303-14-45
Variable Valve Timing (VVT) Oil Control Solenoid(29 233 0)

Removal
1. Torque: 10 Nm
x2
E92954
2. Torque: 10 Nm
E67949
Installation
2008.50 Kuga 8/2011
G970800en

TO MODEL INDEX
303-14-46
303-14-46
Brake Pedal Position (BPP) Switch(33 502 0)

Removal
1.

E101878
Installation
1.

2008.50 Kuga 8/2011
G1065472en

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303-14-47
303-14-47
Clutch Pedal Position (CPP) Switch(33 503 0)

Removal
1.

45
2
E101866
Installation
1.

2008.50 Kuga 8/2011
G1065474en
Automatic
307-01-1

TO MODEL INDEX
Transmission/Transaxle Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01-1
SECTION 307-01 Automatic Transmission/Transaxle

Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD

CONTENTS
PAGE
PAGE 1 OF 3
SPECIFICATIONS
Specifications......................................................................................................................
307-01-4

Transmission Description (Component Location)...............................................................
Transmission Description (Overview).................................................................................
Components of the AW55 automatic transaxle..................................................................
Transaxle cooling............................................................................................................
External shift mechanism................................................................................................
Components of the electronic control.............................................................................
Overview of the brakes, clutches and one-way clutches................................................
Input and output signals at the TCM...............................................................................
Knowing and Understanding Customer Concerns..........................................................
Testing Possible Causes of Transmission Control Faults...............................................
IDS Diagnosis.................................................................................................................
visual inspection.............................................................................................................
Towing the vehicle..........................................................................................................
Push-starting the Vehicle................................................................................................
Jump-starting the Vehicle...............................................................................................
Selector Lever Emergency Release...............................................................................
Adjusting the Selector Lever Cable................................................................................
Transmission Fluid Level Check.....................................................................................
Changing the Transmission Fluid...................................................................................
Diagnosis with IDS..........................................................................................................
Resetting the counter for fluid change intervals..............................................................
Programming the 'N' position of the TR sensor..............................................................
Resetting the values learned by the TCM.......................................................................
Transmission Description (System Operation and Component Description).....................
Functionality overview....................................................................................................
Electronic Control System..............................................................................................
Hydraulic Control System...............................................................................................
Type plate.......................................................................................................................
Serial number of the transmission..................................................................................
Markings on the TCM.....................................................................................................
Serial number of the TCM...............................................................................................
Transmission Control......................................................................................................
Pin assignment for TCM connector 'C' (connection to transaxle)...................................
Operation........................................................................................................................
Gearshift control..............................................................................................................
Adaptation.......................................................................................................................
Shifting from 'P' to another transmission range..............................................................
307-01-5
307-01-6
307-01-6
307-01-6
307-01-8
307-01-8
307-01-9
307-01-11
307-01-12
307-01-14
307-01-14
307-01-14
307-01-14
307-01-15
307-01-15
307-01-15
307-01-15
307-01-16
307-01-17
307-01-17
307-01-18
307-01-19
307-01-19
307-01-19
307-01-21
307-01-21
307-01-22
307-01-24
307-01-24
307-01-24
307-01-25
307-01-25
307-01-25
307-01-25
307-01-27
307-01-28
307-01-29
307-01-29
307-01-29
Automatic
307-01-2

TO MODEL INDEX
307-01-2
.
PAGE 2 OF 3
Automatic transmission, selector lever in position "D"....................................................

Sport mode, selector lever in position "S".......................................................................
Changing gear in select-shift mode................................................................................
Selector lever from 'N' to 'R' position..............................................................................
Self-test and Diagnosis...................................................................................................
Temperature controlled torque converter lockup............................................................
Slip locking......................................................................................................................
Hill climbing.....................................................................................................................
Downhill driving...............................................................................................................
Hill-hold function.............................................................................................................
Altitude correction...........................................................................................................
Selector lever lock..........................................................................................................
Shifting from P into another transmission range.............................................................
Shifting from N into another transmission range.............................................................
Power flow through the transmission..............................................................................
Clutches and brakes.......................................................................................................
Position P (park).............................................................................................................
Position N (neutral).........................................................................................................
Position D, 1st gear........................................................................................................
Position D, 2nd gear.......................................................................................................
Position D, 3rd gear........................................................................................................
Position D, 4th gear........................................................................................................
Position D, 5th gear........................................................................................................
Position R (reverse)........................................................................................................
Service instructions.........................................................................................................
Towing procedure...........................................................................................................
Reset adaptation data.....................................................................................................
Limp home mode............................................................................................................
Tasks of the electronic components................................................................................
Input signals....................................................................................................................
Output signals.................................................................................................................
Control valve assembly...................................................................................................
Shift solenoids S1 - S5...................................................................................................
PWM- solenoid valve TCC (SLU)................................................................................
PWM solenoid valve shift pressure (SLS)...................................................................
PWM solenoid valve for main line pressure (SLT)..........................................................
Installation position.........................................................................................................
Operation........................................................................................................................
Selector lever with integrated select-shift switch module...............................................
Oil pump..........................................................................................................................
Torque converter with TCC.............................................................................................
The TSS sensor..............................................................................................................
The OSS sensor.............................................................................................................
The TFT sensor..............................................................................................................
The TR sensor................................................................................................................
307-01-29
307-01-29
307-01-29
307-01-30
307-01-30
307-01-30
307-01-30
307-01-30
307-01-31
307-01-31
307-01-31
307-01-31
307-01-31
307-01-31
307-01-31
307-01-31
307-01-33
307-01-34
307-01-35
307-01-36
307-01-37
307-01-38
307-01-39
307-01-40
307-01-41
307-01-41
307-01-42
307-01-42
307-01-42
307-01-42
307-01-44
307-01-45
307-01-45
307-01-47
307-01-49
307-01-50
307-01-51
307-01-52
307-01-52
307-01-53
307-01-54
307-01-55
307-01-56
307-01-57
307-01-58
307-01-60
GENERAL PROCEDURES
Transmission Fluid Level Check.........................................................................................
Transmission Fluid Drain and Refill....................................................................................
307-01-61
307-01-63

Halfshaft Seal LH................................................................................................................
Halfshaft Seal RH...............................................................................................................
Main Control Valve Body....................................................................................................
307-01-67
307-01-68
307-01-69
Automatic
307-01-3

TO MODEL INDEX
307-01-3
.
PAGE 3 OF 3
Output Shaft Speed (OSS) Sensor.....................................................................................

Torque Converter Seal........................................................................................................
Transmission Fluid Pan......................................................................................................
Transmission Range (TR) Sensor......................................................................................
Turbine Shaft Speed (TSS) Sensor....................................................................................
307-01-72
307-01-73
307-01-75
307-01-77
307-01-81
REMOVAL
Transmission......................................................................................................................
307-01-82
INSTALLATION
Transmission......................................................................................................................
307-01-91
Automatic
307-01-4

TO MODEL INDEX
307-01-4
SPECIFICATIONS
Item
Specification
Automatic transmission fluid
WSS-M2C924-A
Capacities
Litres
Automatic transmission fluid (including cooler an cooler hoses)
7.7 0.2
Gear Ratio
Gear Ratio
1st gear
4.576
2nd gear
2.980
3rd gear
1.948
4th gear
1.318
5th gear
1.000
Reverse gear
5.024
Counter gear
1.018
Differential gear
2.652
Line Pressure Chart

TransmisIdle (bar)
sion
Range
Idle (kPa)
Idle (psi)
Stall (bar)
Stall (kPa)
Stall (psi)
4,9 - 6,1
490 - 610
71 - 88
17,1 - 19,9
1710 - 1990
248 - 289
3,3 - 3,9
330 - 390
48 - 57
12,9 - 14,1
1290 - 1410
187 - 205
2008.50 Kuga 8/2011
G1163602en
Automatic
307-01-5

TO MODEL INDEX
307-01-5
Transmission Description Component Location

AW55 automatic transaxle
E112283
2008.50 Kuga 8/2011
G1163603en
Automatic
307-01-6

TO MODEL INDEX
307-01-6
Transmission Description Overview

Components of the AW55 automatic
transaxle
6
5
E112298
Item
Description
Item
Description
Torque converter
Planetary gear set.
Differential
The TSS (turbine shaft speed) sensor
The OSS (output shaft speed) sensor
Control valve assembly
General overview
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-7

TO MODEL INDEX
307-01-7
E125525
Design:
The gear ratios are achieved by means of a
combined planetary gear set on the input side
and a Simpson set on the output side.
The combined planetary gear set consists of
two different, simple planetary gear sets. It
has a similar structure to a Ravigneaux set,
but with just one sun gear that engages with
the front planetary gears.
Three multi-plate clutches
Four multi-plate brakes
One band brake

Two one-way clutches
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc.
The TCM features a self-learning strategy.
This leads to lower fuel consumption together with
improved comfort through smoother gear changes
and lower noise levels.
Gear ratios of the individual gears

Gear
Transmission Ratio
First
4.576
Second
2.980
Third
1.948
Fourth
1.318
5th
1.000
Reverse
5.024
Intermediate shaft
1.018
Differential
2.652
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-8

TO MODEL INDEX
307-01-8

Transaxle cooling
1
4
E112583
Item
Description
The transmission fluid cooler.
Quick-release couplings
The transmission fluid cooler is mounted on the

radiator. The transmission fluid cooler and the
automatic transaxle are connected via two hose
lines, which are equipped with quick-release
couplings.
Item
Description
From transmission fluid cooler to

transmission
From transmission to transmission fluid

cooler
The transmission fluid cooler operates according

to the heat exchanger principle. The ram air
passing through the radiator withdraws heat from
the transmission fluid.
External shift mechanism
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-9

TO MODEL INDEX
307-01-9
8
7
E112582
Item
Description
Gear selector mechanism
Selector lever cable guide
Selector cable
Damper weight
The transmission range selector is located on the

center console and is mechanically connected to
the transmission by a cable for operation of the
gear selector shaft and the TR (transmission range)
sensor.
As well as the positions P/R/N/D, the transmission
range selector provides a position for the sport and
select-shift mode (S). The manual gear position
can be selected at any time while driving. The gear
2008.50 Kuga 8/2011
Item
Description
Adjusting mechanism for selector lever

cable
Shift valve shaft lever
Selector lever cable bracket
Retaining clip
Emergency release lever
selected is locked until the driver selects another

gear.
The engine can only be started in 'P' or 'N' position.
The selector cable adjustment mechanism is at the
transmission end of the selector cable.
Components of the electronic control
G1163604en
Automatic
307-01-10

TO MODEL INDEX
307-01-10
1
12
2
11
4
5
10
E112323
Item
Description
Item
Description
The TSS sensor
Shift solenoid S3
The OSS sensor
Shift solenoid S5
PWM (pulse width modulation)- solenoid

valve TCC (torque converter clutch)
(SLU)
Shift solenoid S2
10
The TFT (transmission fluid temperature)

sensor
PWM solenoid valve shift pressure (SLS)
11
Shift solenoid S1
PWM solenoid valve for main line pressure

(SLT)
Shift solenoid S4
12
TCM with integrated TR sensor
Depending on the input signals, the TCM mounted

on the transaxle actuates the solenoid valves
S1-S5 in the valve body. The solenoid valves are
either in the "open" or "closed" state.
The (SLT and SLS) control valves regulate the
hydraulic pressure according to the pulse/pause
ratio of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes.
2008.50 Kuga 8/2011
The shift timing is calculated by the TCM using the

accelerator pedal position and vehicle speed.
Under normal conditions, gear shifting and torque
converter lockup occur at low engine speeds to
reduce fuel consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163604en
Automatic
307-01-11

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307-01-11

Function of the shift solenoids in the gears
Gear
S1
S2
S3
S4
S5
On
On
On
Off
Off
Off
Off
On
Off
Off
Off
Off
On
On
Off
Off
Off
Off
On
Off
Off
On
Off
On
Off
Overview of the brakes, clutches and

one-way clutches
1
4
5
13
12
E112793
Item
Description
Item
Description
Clutch C2: Connects the input shaft with

the sun gear.
Brake B1: Locks the sun gear on the input

shaft.
Clutch C1: Connects the input shaft with

the rear gear.
Brake B3: Locks the annulus of the front

planetary gear.
One-way clutch F1: Prevents the sun gear

on the input shaft turning counterclockwise
when B2 is activated.
Park System
One-way clutch F2: Locks the front

annulus in the counterclockwise direction.
Brake B2: Prevents the sun gear on the

input shaft from turning counterclockwise.
Clutch C3: Connects the sun gear with the

front planetary gear carrier on the output
shaft.
10
Brake band B4: Blocks the the sun gear

on the output shaft.
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-12

TO MODEL INDEX
307-01-12

Item
Description
Item
Description
11
Brake B5: Locks the rear planetary gear

carrier on the output shaft.
12
Output shaft transaxle
13
Input shaft transaxle
Function of the clutches and brakes in the gears and during gear changes.
Gear
C1
C2
C3
B1
B2
B3
B4
B5
F1
F2
Park
Off
Off
Off
Off
Off
Off
Off
On
Off
Off
R
(V<=7)
Off
On
Off
Off
Off
On
Off
On
Off
Off
R
(V>7)
Off
Off
Off
Off
Off
Off
Off
On
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
Off
Off
On
Off
Off
Off
Off
Off
Off
On
Off
On
1<=>2
On
Off
Off
Off-On
Off-On
Off
Off
On
Off-On
On-Off
On
Off
Off
On
On
Off
Off
On
On
Off
2<=>3
On
Off
Off
On
On
Off
On
Off
On
Off
Off
On
On
Off
On
Off
On
Off
3<=>4
On
Off
Off-On
On
On
Off
On-Off
Off
On
Off
On
Off
On
On
On
Off
Off
Off
On
Off
4<=>5
On
Off-On
On
On-Off
On
Off
Off
Off
On-Off
Off
On
On
On
Off
On
Off
Off
Off
Off
Off
Off-On On-Off
V = vehicle speed in km/h

x<=>x = gear change up/down
TCM
The TCM with integral TR sensor is mounted on

the transaxle casing.
Input and output signals at the TCM
E112322
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-13

TO MODEL INDEX
307-01-13
18
19
20
21
17
16
15
14
1
13
12
2
11
3
10
8
7
E112805
Item
Description
Item
Description
TCM
Instrument Cluster
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-14

TO MODEL INDEX
307-01-14

Item
Description
Item
Description
ABS (anti-lock brake system)
13
Shift solenoid S1 (open when dormant)
Speed control
14
Shift solenoid S2 (closed when dormant)
Select-shift switch module
15
PCM
16
Selector lever lock
17
10
18
The TSS sensor
11

(SLT)
19
The OSS sensor
20
The TFT sensor
12
PWM- solenoid valve TCC (SLU)
21
TR sensor in TCM
Knowing and Understanding Customer

Concerns
Knowing and understanding customer concerns is
necessary in order to perform diagnosis.
First of all, ask the customer under which operating
conditions the problem occurs. If possible, try to
reproduce the concern by road testing the vehicle
with the customer.
You should be familiar with the following operating
conditions:
Engine operating state
Cold, warm-up phase, or at operating
temperature
Ambient temperature
Below 0 C (32 F), 0 to 20 C (32 to 68 F),
or above 20 C (68 F)
Road conditions
Good, poor, or off-road
Vehicle load status
Unloaded, loaded, or fully loaded
Transaxle status in manual mode
Upshift, downshift, overrun or acceleration
Testing Possible Causes of Transmission

Control Faults
Before performing a symptom-based diagnosis,
first carry out checks to eliminate various other
potential causes of the fault.
These situations include:
Battery state of charge
Defective fuses
2008.50 Kuga 8/2011
Loose or corroded cables or electrical

connectors
Ground connections to the transmission
Retrofitted add-on units which are not approved
by Ford, such as air conditioning, car telephone,
cruise control
Unapproved tire sizes
Incorrect tire size programmed with IDS
(Integrated Diagnostic System)
Engine tuning
IDS Diagnosis
NOTE: Customer concerns relating to the transaxle
can also be caused by engine-related faults.
The transmission control system of the AW55 is
closely linked to the engine management system.
Faults in the engine management system may
affect the transmission control system.
Before repairing the transaxle, it should be ensured
that the fault is not caused by the engine
management system or other non-transaxle
components.
The diagnosis can be performed on the AW55 with
the aid of von IDS.
visual inspection
A thorough visual inspection of the transaxle is
necessary for successful diagnosis.
A visual inspection is made of the following
components:
Connectors and plug connections
Ease of operation of the selector lever
G1163604en
Automatic
307-01-15

TO MODEL INDEX
307-01-15

Jump-starting the Vehicle
Selector lever position and selector lever

position display
Fluid leakage
Transmission fluid level check
Transmission fluid quality check
Modification/retrofitting
Mechanical damage to the transmission
NOTE: When jump-starting the vehicle, the external

battery must remain connected for several minutes.
When inspecting connectors, remember that the

plugs may only be disconnected when they are not
energized.
The voltage peaks dissipate after a few minutes.

Only then may the external battery be disconnected
without the risk of damage.
The transaxle electronics may be destroyed by

static charge. To prevent damage, it must be
ensured that the technician complies with the
corresponding safeguards.
Selector Lever Emergency Release
CAUTION: When jump-starting the vehicle

using a jumper lead there may be voltage
peaks. These may destroy the transaxle
electronics.
NOTE: Refer to the service literature for an exact

description of these safeguards.
3
Towing the vehicle
4
1
E66463
In general, vehicles with the AW55 transaxle can

be towed. Vehicles must never be towed
backwards.
As a result of the reduced lubrication of the
transaxle during towing, the following must be
remembered:
The selector lever must be in the 'N' position.
The maximum towing speed must not exceed
50 km/h.
The maximum towing distance must not exceed
50 kilometers.
Push-starting the Vehicle

No torque is transmitted when towing or pushing
the vehicle. For this reason, vehicles with an
automatic transaxle cannot and must not be
tow-started or push-started.
2008.50 Kuga 8/2011
E114512
If release of the selector lever lock by means of

the selector lever lock solenoid actuated by the
TCM fails in selector lever position 'P', it is possible
to perform an emergency release.
Procedure:
Carefully slide a flat screwdriver into the slot (1).
Turn the screwdriver (2).
Press the screwdriver downwards to detach the
gaiter frame from the trim panel (3).
G1163604en
Automatic
307-01-16

TO MODEL INDEX
307-01-16

Press the gaiter frame to move the emergency
release downwards and move the selector lever
out of position P (4).
Pull the gaiter upwards until the gaiter frame
engages in the gaiter frame.
Adjusting the Selector Lever Cable

NOTE: Refer to the service literature for the exact
procedure and specifications.
E126012
The selector lever cable is adjusted in selector

lever position 'N'.
E126013
The selector lever and the gearshift mechanism

must be in the 'N' position. In the case of the
gearshift mechanism it must be ensured that the
markings on the TCM and on the gearshift
mechanism are opposite each other.
Close the lock on the transaxle-side adjusting
mechanism.
E114414
Release the lock on the transaxle-side adjusting

mechanism.
2008.50 Kuga 8/2011
G1163604en
Automatic
307-01-17

TO MODEL INDEX
307-01-17

Transmission Fluid Level Check
the transmission fluid level is excessively low, this

becomes noticeable by a rattling noise at the fluid
pump, etc.
Always use transmission fluid to the indicated
specification (WSS-M2C924-A).
The transmission fluid temperature is determined
using IDS.
It must be ensured that the transmission fluid
temperature is within the range specified in the
workshop literature.
E126079
WARNING: Beware, risk of scalding when

checking the transmission fluid.
NOTE: Refer to the service literature for the exact
In order for the transaxle to function properly, it is
vital that the transmission fluid level is correct. If
2008.50 Kuga 8/2011
The following conditions must be met in order to

carry out the transmission fluid level check
correctly:
Ensure that the transaxle is not in limp home
mode.
Place the vehicle on a level surface.
Move the selector lever to the 'P' position.
Make sure that the parking brake is fully applied.
Run the engine at idle speed.
Move the transmission selector lever to all
positions. In doing so, wait until the transmission
engages the corresponding range.
Move the selector lever back to the 'P' position.
Pull out the fluid dipstick.
When the predetermined transmission fluid
temperature is reached, the fluid level shown on
the dipstick must be in the middle between 'MIN'
and 'MAX'. In this case, the fluid level is correct.
Changing the Transmission Fluid
G1163604en
Automatic
307-01-18

TO MODEL INDEX
307-01-18
E126062
Item
Description
Item
Description
Fluid reservoir
Connection for return line on transaxle
Connection for return line from fluid cooler
Hose
Under normal conditions, the transmission fluid is

filled for the service life of the transaxle and does
not need to be changed.
Under high loads (driving with a trailer or in
mountains etc.) it may be necessary to change the
transmission fluid.
To drain the transmission fluid, remove the fluid
drain plug.
Proceed as follows when topping off the
transmission fluid:
Remove the return line from the fluid cooler to
the transaxle on the transaxle. Close off the
connection on the transaxle using a plastic plug.
Join the return line to a transparent pipe. The
transparent pipe ends in the fluid reservoir in
order to collect the fluid.
To top off the transmission fluid, insert a
transparent pipe in the guide tube of the dipstick
and add approx. 2.0 liters of transmission fluid.
Move the selector lever to the 'P' position and

allow the engine to run at idle speed.
Switch off the engine if air bubbles become
visible in the transparent pipe to the fluid
reservoir.
Top off approx. 2 liters of transmission fluid and
allow the engine to run at idle speed. Switch off
the engine if air bubbles become visible in the
transparent pipe to the fluid reservoir.
Top up the transmission fluid until the fluid level
for cold fluid is indicated on the dipstick in the
middle between 'MIN' and 'MAX'.
Then check the transmission fluid level.
Refer to the service literature for the exact
NOTE: If the transmission fluid has been changed,
the counter for fluid change intervals must be reset
using IDS.
Diagnosis with IDS

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E77584
NOTE: Due to static charging, measurements

inside the transaxle using a multimeter are
prohibited.
Stored DTCs in the engine management system
may affect transmission control. As a result, faults
in the transmission control system and engine
management system must be rectified in
accordance with the symptom-based diagnosis in
FordEtis IDS.
Applications of IDS Standard include:
Resetting the counter for fluid change intervals.
Programming the selector lever position 'N'.
Resetting the values learned by the TCM.
Resetting the counter for fluid change

intervals.
This function must be performed if the transmission
fluid has been changed or a new automatic
transaxle has been installed with the previous TCM.
This function resets the values stored for the
pollution level of the transmission fluid.
2008.50 Kuga 8/2011
Programming the 'N' position of the TR

sensor
This function must be executed if
the TCM with integrated TR sensor is renewed,
a new automatic transaxle is installed with the
previous TCM.
the selector lever cable or the selector
mechanism assembly is renewed
TR have been set due to a fault in the selector
lever assembly or in the DTC (diagnostic trouble
code) sensor.
The TCM learns and stores the voltage value in
the 'N' position when this function is executed.
Resetting the values learned by the TCM

This function must be executed if
a new automatic transaxle is installed with the
previous TCM.
a component of the automatic transaxle has
been renewed.
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The learned values are reset. Resetting the learned
values can briefly impair shifting quality until the
TCM has learned and stored the new values.
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Transmission Description System Operation and Component

Description
System Operation
E112576
The AW55 5-gear automatic transaxle is a fully

automatic, electronically controlled automatic
transaxle. The fifth gear is an overdrive which
saves fuel.
The maximum input torque is 330 Nm.
Gear changes are controlled by an
electro-hydraulic system.
The gear ratios are achieved by means of a
combined planetary gear set and a Simpson set.
Three multi-plate clutches, four multi-plate brakes
and one band brake as well as two one-way
clutches control the various ratios.
The clutches and brakes are hydraulically operated
by electrically actuated solenoid valves. The valves
are actuated by the TCM depending on the driving
conditions and the driver's requirements.
The TCC is activated in gears 3, 4 and 5. The TCC
is driven in interlock mode and in slip mode.
2008.50 Kuga 8/2011
Defined slip achieves a smooth and therefore

comfortable clutch engagement of the TCC.
Control of slip mode depends on the engine speed,
accelerator pedal position and vehicle speed
signals provided by the ECM (engine control
module). This controls the rate of slip by comparing
the engine speed and the turbine shaft speed.
The TSS sensor and the OSS sensor use the Hall
effect principle. The TCM can regulate the slip in
the torque converter by comparing the engine
speed with the transmission speed.
All parameters for actuating the clutches and the
TCC are determined by the TCM as a function of
the operating parameters. The automatic transaxle
features a self-learning strategy.
The fundamental parameters for gear shifting are
the accelerator pedal position and the vehicle
speed.
Gear selection can either be performed
automatically or in select-shift mode. The selected
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transmission range or gear (in select-shift mode)
is indicated to the driver in the instrument panel.
In selector lever position "S", the driver can
manually select the gears (select-shift mode). Up
(+) and down (-) shifts are made by moving the
selector lever in the appropriate direction.
Hydraulic limp home modes maintain limited
operation in the event of failure of important
electrical components.
2008.50 Kuga 8/2011
Under normal conditions, the transmission fluid is

filled for the service life of the transaxle and does
not need to be changed.
A dipstick is used to check the fluid level in the
transmission.
Functionality overview
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E125524
Item
Description
Item
Description
Electronic Control System
Hydraulic Control System
CAN (controller area network) bus input

signals
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Item
Description
Item
Description
The TR sensor
OSS (output shaft speed) sensor
The TSS sensor
Solenoid valves in valve body
The TFT sensor
Clutches and brakes
TCM
10
TCC
The function is divided into an electronic and a

hydraulic control system.
pressure required for controlling the automatic

transaxle.
The TR sensor is integrated in the TCM.
Through actuation of the solenoid valves, hydraulic

pressure is applied to the clutches and brakes via
hydraulic channels in the valve body and the
transaxle. The control valves regulate the hydraulic
pressure in accordance with the duty cycle of the
electrical PWM signal. The controlled hydraulic
pressure enables smooth shifting or the generation
of a defined slip through actuation of the relevant
clutches and brakes.
Hydraulic Control System
Solenoid valves are either in the 'open' or 'closed'

state.
When the engine is running, a fluid pump integrated

in the transaxle housing generates the hydraulic
Type plate
Electronic Control System

on the transmission actuates the solenoid valves
in the valve body. The TCM calculates and stores
adaptive data, fault codes and values for diagnosis.
E125523
The transaxle identification is located on the

rear/top of the transaxle housing in the direction of
travel.
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Serial number of the transmission
Example: 09HV70001
09: year of manufacture, 2009
Identification letter coding
A
H: code letter for the month of manufacture,

August
V7: automatic transaxle type 55-51SN
00001: Production number for the specified
month
January
February
March
April
May
June
July
H.
August
September
October
left-hand
November
Ground
December
Markings on the TCM
The name plate is located on the TCM.
Serial number of the TCM

Example: 082200001
08: year of manufacture, 2008
22: code for the calendar week
00001: Production number for the specified
calendar week
Transmission Control
The TR sensor is integrated in the TCM.
E125774
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various transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
E112322

etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only
controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts the
To exactly determine the activation points of the

gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
Transmission range chosen (TR sensor).
Type of driving mode chosen
(normal/sport/select-shift).
Transmission input shaft speed (TSS sensor).
Transmission output shaft speed (OSS sensor).
Transmission fluid temperature (TFT sensor).
The engine speed and the torque as well as the
throttle plate opening - from the PCM via the
CAN data bus.
Actuation of the accelerator pedal - from the
PCM via the CAN data bus.
Coolant temperature - from the PCM via the
CAN data bus.
Vehicle speed - from the ABS via the CAN data
bus.
Actuation of the brake pedal - from the ABS via
the CAN data bus.
Pin assignment for TCM connector 'A' (connection to vehicle)
11
E125669
Item
Description
Item
Description
Battery (+)
not assigned
not assigned
not assigned
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Item
Description
Item
Description
Starter motor inhibitor signal to the PCM
11
Battery (+) via ignition switch
CAN (low)
12
not assigned
LIN (local interconnect network)
13
Selector lever lock
CAN (high)
14
not assigned
GND (ground)
15
not assigned
10
not assigned
16
Voltage supply for select-shift switch

module
Pin assignment for TCM connector 'B' (connection to transaxle)
E125670
Item
Description
Item
Description
OSS()
TSS(+)
OSS(+)
TSS()
Pin assignment for TCM connector 'C'

(connection to transaxle)
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22 21 20 19
18 17 16 15 14 13 12
11 10 9 8 7 6 5
4 3 2 1
E125671
Item
Description
Item
Description
Shift solenoid valve S1 (+)
11
not assigned
Shift solenoid valve (S2) (+)
12
not assigned
PWM solenoid valve main line pressure

(SLT) (+)
13
TFT sensor ()
14
TFT sensor (+)
not assigned
15
not assigned
not assigned
16
PWM solenoid valve main pressure line

(SLT) ()

(+)
17
PWM solendoid valve TCC (SLU) ()
18
not assigned
not assigned
19
not assigned
PWM solenoid valve TCC (SLU) (+)
20
not assigned
10

()
21
22
Operation
etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only
2008.50 Kuga 8/2011
controlled hydraulically, the control module can

calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts the
various transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
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To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
Selected transmission range (TR sensor)
Selected driving mode (normal/sport/select-shift)
Transmission input shaft speed (TSS sensor)
Transmission output shaft speed (OSS sensor)
Transmission fluid temperature (TFT sensor)
The engine speed and the torque as well as the
throttle plate opening - from the PCM via the
CAN databus
Actuation of accelerator from the PCM via the
CAN databus
The coolant temperature from the PCM via
the CAN databus
Road speed from the ABS module via the
CAN databus
Actuation of brake pedal from the PCM via
the CAN databus
Gearshift control
Adaptation
The TCM monitors every shift operation in all
driving conditions to make even and smooth gear
shifts possible. This is done by the control module,
which either lowers or increases the hydraulic line
pressure during gearshifts.
The changed pressure values are stored in the
control module memory after the engine is switched
off and retrieved during engine starting. This
improves the shift comfort and extends the service
life.
Full adaptability occurs when the following criteria
are met:
Throttle plate opening is constant.
Transmission fluid temperature between 65 C
and 110 C.
Shifting from 'P' to another transmission

range
To be able to move the selector lever from 'P' into
another transmission range, the ignition must be
switched on and the brake pedal pressed (stoplamp
switch on). The TCM detects the position of the
brake pedal via the CAN data bus and the engaged
transmission range from the TR sensor.
2008.50 Kuga 8/2011
Based on this information, the TCM transmits a

signal to the select-shift switch module. This
activates the brake shift interlock actuator in the
selector lever assembly.
When the brake shift interlock actuator is activated,
the locking pin is retracted so that another
transmission range can be selected.
The brake shift interlock actuator is deactivated
when the ignition is switched off. It is mechanically
locked when the gear selector lever is in 'P'.
Automatic transmission, selector lever in

position "D".
The TCM adapts the shift points to match the
driving conditions. Normally the TCM is in adaptive
mode and gear changes take place adapted to the
driving conditions. If special driving conditions are
detected, the TCM switches to predefined
characteristics.
When driving with normal acceleration, the TCM
uses a preset shift program which is optimized for
economical driving.
This shift program is suitable for "normal" driving
and delivers early upward changes and torque
converter lockup. Furthermore, the transmission
fluid pressure is adapted to make smooth
engagement of the gears possible.
Sport mode, selector lever in position "S"

The transmission switches from automatic
operation into sport mode. In this mode the TCM
switches to another set of characteristic curves.
These characteristic curves for control of the gear
changes are adapted to sporting calculations (e.g.
gear change at higher engine speed).
In the sport mode shift program the shift points are
set so that good performance is offered. Changing
down occurs at lower engine speeds.
Manual gear changes (select-shift mode) can be
made in sport mode by moving the selector lever
in the (+) or (-) direction.
Changing gear in select-shift mode

If you move the selector lever to 'S', the automatic
transaxle remains hydraulically in 'D' position. If
you move the gear selector lever forwards (-), the
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select-shift switch module transmits a downshift
signal to the TCM.
If you move the gear selector lever backwards (+),
an upshift signal is transmitted to the TCM. In the
instrument cluster, the symbol when the selector
lever is in the 'S' position changes from 'D' to the
current gear, for example 3.
The TCM transmits a signal to the select-shift
switch module to switch on the light emitting diode
for 'S' and to switch off all other light emitting
diodes. The TCM decides whether the shift process
is possible.
If the shift process is permitted, then the various
valves are activated according to the intended
combination for each gear.
In certain situations however, the TCM determines
the gear shifting. The following applies:
If the vehicle is stationary, only 1st, 2nd and 3rd
gears can be selected. 4th gear can be selected
at speeds over 30 km/h and 5th gear at speeds
over 40 km/h.
The kickdown function is only available in the
automatic transmission range 'D'
Automatic gear changes into the next higher or
next lower gear occur at fixed vehicle speeds
and fixed engine speeds
The permitted engine speed for manual change
down agree with that for the kickdown change
up, i.e. an engine speed of approximately 6000
rpm.
If the temperature inside the transmission rises
too high, the TCM takes control of the shift
decisions in order to select a gear in which
activation of torque converter lockup at the
current speed is possible
Torque converter lockup is possible in 3rd, 4th
and 5th gear. (1st and 2nd gears do not have
torque converter lockup)
The signal that specifies the position of the lever
to the select-shift switch module is generated as
follows in the selector lever position 'S': there is a
Hall sensor at the printed circuit board for the
module for each of the three selector lever
positions. A permanent magnet on the cover in the
selector lever affects the output signals to the
control module from the sensors. The control
module recognizes the position of the lever by the
differences in the signal properties.
Selector lever from 'N' to 'R' position

The TCM only permits shifting to reverse gear if
the vehicle speed is less than 4.35 mph.
If the vehicle speed is greater than 7 km/h (approx.
4.35 mph), the clutch (C2) and the multi-plate brake
(B3) are not activated and the gearshift is thus
prevented.
Self-test and Diagnosis

The TCM monitors all the transaxle sensors and
electronic components including the PCM. If a fault
occurs, the driver is informed via a warning
indicator and a text message in the instrument
cluster. Faults are stored as DTCs in the fault
memory of the TCM and can be read out and
cleared using the IDS.
Temperature controlled torque converter

lockup
If heavy load and high ambient temperatures cause
an abnormal rise in the transmission temperature,
torque converter lockup is activated as often as
possible (temperature controlled lockup).
This reduces the slip and the heat developed in
the transmission. When the temperature drops
below +20 C, torque converter lockup is not used.
Slip locking
When changing gear this function makes it possible
for the gears to engage more smoothly with
reduced vibration and less noise. In this mode, the
torque converter clutch is activated but not fully
locked.
The following conditions must be met for the
function to activate:
Gear selector lever in position D or S.
Gear 3, 4 or 5.
The transmission input speed is 1100 rpm or
more and the throttle plate opening 20 - 35%.
The transmission fluid temperature is 40 - 120
C.
Hill climbing
The TCM can change the shift pattern slightly when
driving uphill to avoid changing gear too often.
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The TCM detects uphill driving by comparing the
engine load transmitted by the PCM with the engine
speed. If the engine load increases and the engine
speed falls, then the TCM causes the transaxle to
shift to a lower transmission range in order to
increase the traction force.
Downhill driving
The TCM detects downhill driving by comparing
the engine load and engine speed values
transmitted by the PCM with the OSS sensor
signal. In order to prevent overloading of the
vehicle brakes, the TCM causes the transaxle to
shift to a lower transmission range.
Hill-hold function
If the vehicle is stopped on an uphill incline, the
TCM detects this through the faster drop in engine
speed compared with the drop in engine speed
when stopping on the flat. In this situation, the
hydraulics are actuated by the TCM in such a way
that the vehicle is prevented from rolling back. This
function is not used on steep inclines.
If the vehicle is parked on an uphill incline (ignition
switched off), the hill-hold function is not active
when pulling away.
Altitude correction
Lower air density results in reduced engine
performance. In order to compensate for this
operating situation, the TCM changes the shift
points.
Shifting from P into another transmission

range
To be able to move the selector lever from P into
another transmission range, the ignition must be
switched on and the brake pedal must be
depressed (stop light switch on). The TCM detects
the position of the brake pedal via the CAN data
bus and the engaged transmission range from the
TR sensor.
The signal is then transferred from the TCM to the
select-shift switch module in order to activate the
solenoid valve in the selector mechanism
assembly.
In position P, the solenoid valve is activated and
the locking pin is pulled in so that the lock button
on the selector lever can be pressed as usual to
engage another transmission range.
In the selector mechanism assembly there is a Hall
sensor which is affected by a permanent magnet
on the gate of the selector mechanism assembly.
If the selector lever is moved from the P position,
both the Hall sensor and the selector lever lock
solenoid are simultaneously deactivated, to prevent
the selector from being kept in the N position.
If the ignition is set to "I" or "0" the solenoid valve
is deactivated. When the selector lever is in the P
position, it is mechanically locked because it has
no voltage.
Shifting from N into another transmission

range
The conditions are the same as for shifting from P
into another transmission range.
However, the lock button on the selector lever must
be pressed to be able to select R or P.
Selector lever lock

To prevent the selector lever being accidentally
moved from the P or N position, the vehicle also
has an electrically operated selector lever lock.
This blocks the locking pin in the locking segment
and thus locks the selector lever in the P or N
position.
2008.50 Kuga 8/2011
Power flow through the transmission

Clutches and brakes
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1
4
5
13
12
E127357
Item
Description
Item
Description
5th gear and reverse gear clutch (C2)
Parking lock
1st - 5th gear clutch (C1)
4th and 5th gear clutch (C3)
Reverse gear brake (B3)
10
3rd gear brake (B4) (band brake)
1st gear one-way clutch (F2)
11
2nd - 5th gear brake (B2)
1st and 2nd gear and reverse gear brake

(B5)
2nd - 4th gear brake (B1)
12
Output shaft transaxle
2nd - 4th gear one-way clutch (F1)
13
Input shaft transaxle
The transaxle features three clutches, five brakes,

and two one-way clutches.
The clutches are designed as multi-plate clutches.
There are four multi-plate brakes (B1, B2, B3, B5)
and one band brake (B4).
Tasks of clutches and brakes
1st-5th gear clutch (C1): Connects the input
side with the ring gear.
5th gear and reverse clutch (C2): Connects
the input side with the sun gear.
4th and 5th gear clutch (C3): Connects the
sun gear with the front planetary gear carriers
on the output side.
2008.50 Kuga 8/2011
2nd-4th gear brake (B1): Locks the sun gear

on the input side.
2nd-5th gear brake (B2): Locks the rotational
movement of the sun gear on the input side in
a counterclockwise direction.
Reverse gear brake (B3) and 1st gear brake
in select-shift mode: Locks the ring gear on
the input side.
3rd gear brake (B4) (band brake): Locks the
two sun gears on the output side.
(B5): Locks the rear planetary gear carriers on
the output side.
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2nd-4th one-way clutch (F1): Locks the
rotational movement of the sun gear on the input
side in a counterclockwise direction, if 2nd-5th
gear brake (B2) is applied.
1st gear one-way clutch (F2): Locks the

rotational movement of the ring gear on the input
side in a counterclockwise direction.
Function of the clutches and brakes in the gears and when shifting gears in automatic mode and
select-shift mode (manual shifting)
Gear
C1
C2
C3
B1
B2
B3
B4
B5
F1
F2
Park
(V<=7)
R
(V>7)
1<=>2
/0
/0
/0
0/
2<=>3
/0
0/
3<=>4
/0
0/
4<=>5
/0
0/
0/
V = Road speed in km/h
0 = Actuated
= Not actuated
x<=>x = Gear change "up/down"
* = Actuated in select-shift mode
Position P (park)
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E125574
Item
Description

(B5)
Parking lock
The transmission input shaft rotates in the

clockwise direction. All clutches and brakes are
deactivated and no force is transferred to the
planetary gear sets.
No force is transferred to the output shaft. The
brake B5 (1) locks the rear planetary gear carrier
2008.50 Kuga 8/2011
on the output side. The parking lock (2) engages

in the output shaft and stops the vehicle rolling
away.
Position N (neutral)
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1
2
E125575
Item
Description
Parking lock

(B5)

clockwise direction. All clutches and brakes on the
input side are deactivated and no power is
transmitted to the planetary gear sets.
No force is transferred to the output shaft. The
brake B5 (2) locks the rear planetary gear carrier
on the output side. The parking lock (1) is not
activated. Since the transaxle input shaft is not
positively connected with the input side, the vehicle
will start to roll away if it is on an incline.
2008.50 Kuga 8/2011
The brake B5 is activated both in 'P' and in 'N'

position to reduce the cut-in pressure that
otherwise occurs if several brakes and clutches
are activated simultaneously when the selector
lever is moved to 'D' or 'R' position. Since the brake
B5 is activated both in first and second as well as
in reverse gear, this method reduces the total
number of transient effects.
Position D, 1st gear
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1
3
E127358
Input shaft:
clockwise direction. Clutch C1 (1) joins the
transaxle input shaft with the ring gear, which
rotates in clockwise direction. The rear planetary
gear set rotates in the clockwise direction. The
front larger planetary gear set rotates clockwise
with the rear planetary gear set as a single unit.
The front smaller planetary gear set rotates in the
clockwise direction. The front annular gear rotates
counterclockwise. One-way clutch F2 (2) blocks
the front annular gear clockwise rotation.
The front and rear planetary gear carriers are
turned clockwise because of the reactive forces
from the small gear. The primary idler gear rotates
clockwise with the front and rear planetary gear
carriers as one unit.
The front planetary gear set rotates in the clockwise

direction. The sun gear rotates clockwise.
The rear planetary gear set rotates
counterclockwise. Brake B5 (3) prevents rotation
of the rear planetary gear carrier. The rear annular
gear rotates counterclockwise. The front planetary
gear carrier and the final drive pinion rotate
counterclockwise with the rear annular gear as one
unit. The final drive rotates in the clockwise
direction.
Engine braking:
The 1st gear has no engine braking function
because the power flow is interrupted by the
one-way clutch F2 rotating against the locking
direction.
The brake B3 is additionally activated in select-shift
mode to guarantee engine braking.
Output shaft:
The secondary idler gear rotates counterclockwise.
The front annular gear rotates counterclockwise
with the secondary idler gear as a single unit.
2008.50 Kuga 8/2011
Position D, 2nd gear
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1
2
3
4
5
E127359
Input shaft:
clockwise direction. The clutch C1 (1) joins the
transaxle input shaft and the ring gear. The ring
gear rotates in clockwise direction. The planetary
gear set rotates in clockwise direction.
The front larger planet gear rotates clockwise with
the rear planet gear as a single unit. Brakes B2
(2), brake B1 (3) and the one-way clutch F1 (4)
prevent rotation of the sun gear.
turned clockwise by the front larger gear. The
primary idler gear rotates clockwise with the front
and rear planetary gear carriers as one unit.
Output shaft:
2008.50 Kuga 8/2011
with the secondary idler gear as a single unit. The

front planetary gear set rotates in the clockwise
direction.
The sun gear rotates clockwise. The rear planetary
gear set rotates counterclockwise. Brake B5 (5)
prevents rotation of the rear planetary gear carrier.
The rear annular gear rotates counterclockwise.
The front planetary gear carrier and the shaft drive
pinion rotate in counterclockwise direction with the
rear ring gear as one unit. The final drive rotates
in the clockwise direction.
Engine braking:
The power is transferred directly to the
transmission input shaft without one-way clutch
involvement. Engine braking is thus applied.
Position D, 3rd gear
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5
1
2
3
4
E127360
Input shaft:
gear rotates in clockwise direction. The rear
planetary gear set rotates in the clockwise
direction.
the rear planet gear as a single unit. Brakes B2 (1)
and B1 (2) and also the one-way clutch F1 (3)
prevent rotation of the sun gear.
from the front larger gear. The primary idler gear
rotates clockwise with the front and rear planetary
gear carriers as one unit.

with the secondary idler gear as a single unit. The
front planetary gear set rotates in counterclockwise
direction. The brake band B4 (4) locks the
rotational movement of the sun gear.
The front planetary gear carrier rotates in
counterclockwise direction. The front planetary
gear carrier and the shaft drive pinion rotate in
counterclockwise direction with the rear ring gear
as one unit. The final drive rotates in the clockwise
direction.
Engine braking:
Output shaft:
Position D, 4th gear
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-39

TO MODEL INDEX
307-01-39

5
1
2
3
4
E127361
Input shaft:
gear rotates in clockwise direction. The rear
planetary gear set rotates in the clockwise
direction.
the rear planet gear as a single unit. Brake B2 (1),
one-way clutch F1 (3) and brake B1 (2) prevent
rotation of the sun gear.
from the front larger gear. The primary idler gear
rotates clockwise with the front and rear planetary
Output shaft:
2008.50 Kuga 8/2011
The secondary idler gear rotates clockwise. The

front annular gear rotates counterclockwise with
the secondary idler gear as a single unit. Clutch
C3 (4) connects the sun gear with the front
planetary gear carrier.
The front planetary gear set cannot rotate and the
output shaft rotates counterclockwise as a single
unit. The final drive rotates counterclockwise with
the output shaft as a single unit. The final drive
rotates in the clockwise direction.
Engine braking:
Position D, 5th gear
G1163605en
Automatic
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TO MODEL INDEX
307-01-40

1
4
E125594
Input shaft:
transaxle input shaft and the ring gear. Clutch C2
(1) connects the transmission input shaft with the
sun gear.
The brake B2 (3) locks the rotational movement of
the sun gear in a counterclockwise direction.
The rear planetary gear set cannot rotate and the
rear planet gear unit rotates clockwise as a single
unit. The front planetary gear set cannot rotate with
the rear planetary gear set as a single unit. The
front planetary gear unit rotates clockwise as one
unit. The primary idler gear rotates clockwise with
the front planetary gear unit as a single unit.
Output shaft:
2008.50 Kuga 8/2011

with the secondary idler gear as a single unit.
Clutch C3 (4) connects the sun gear with the front
planetary gear carrier.
The front planetary gear set cannot rotate and the
output shaft rotates counterclockwise as a single
unit. The final drive rotates counterclockwise with
the output shaft as a single unit. The final drive
rotates in the clockwise direction.
Engine braking:
Position R (reverse)
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Automatic
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TO MODEL INDEX
307-01-41

2
3
E127362
Input shaft:
The transmission input shaft rotates clockwise.
Clutch C2 (1) connects the transmission input shaft
with the sun gear. The sun gear rotates clockwise.
The rear planetary gear set rotates
counterclockwise. The front larger planetary gear
set rotates counterclockwise with the rear planetary
gear set as a single unit. The front smaller
planetary gear set rotates clockwise.
Brake B3 (2) blocks the ring gear in
counterclockwise direction. The front and rear
planetary gear carriers are turned clockwise by the
front smaller gear. The primary idler gear rotates
counterclockwise with the front and rear planetary
annular gear as one unit. The final drive rotates

counterclockwise.
Engine braking:
NOTE: The clutch C2 and the brake B3 are only
activated at a speed below 7 km/h (approx. 4.35
mph) when shifting from a forward gear to the
reverse gear.
Service instructions
Towing procedure
Output shaft:
The secondary idler gear rotates clockwise. The
front annular gear rotates clockwise with the
secondary idler gear as a single unit. The front
planetary gear set rotates clockwise. The sun gear
rotates in counterclockwise direction.
Brake B5 (3) prevents rotation of the rear planetary
gear carrier. The rear annular gear rotates
clockwise. The front planetary gear carrier and the
final drive pinion rotate clockwise with the rear
2008.50 Kuga 8/2011
Towing is only permitted travelling forwards, at a

maximum speed of 80 km/h and for up 80 km. The
gear selector lever must be in Neutral.
CAUTION: The vehicle must never be
towed backwards under any
circumstances.
G1163605en
Automatic

TO MODEL INDEX
307-01-42
307-01-42

Reset adaptation data
Limp home mode
Adaptation values are stored in the software of the

TCM:
Adaptation should be reset after an internal
component has been exchanged or the whole
transmission has been changed.
The TCM software contains functions which take

control of the transmission if serious faults occur.
The fault characteristic decides which strategies
are to be used.
The adaptation of the transmission is reset via IDS.
The vehicle remains capable of restricted

operation.
The TCM strategy differentiates between four emergency modes adapted to the fault situation:
Mode
Position
Gear
Emergency 1
Emergency 2
Emergency 3 (*)
Emergency 4
D, S+
4th
S-
2nd
Reverse
Reverse
D, S+
3rd
S-
2nd
Reverse
Reverse
D, S+
4th
S-
2nd
Reverse
Reverse
D, S+, S-
4th
Reverse
Reverse
(*) As for Emergency 1 mode, the second gear will however be shifted using other solenoid valves.
Different measures are implemented, depending

on the current gear position and driving situation
when the fault occurs:
When a fault occurs, the TCM makes it possible
for the vehicle to maintain restricted operation.
The distance travelled should be kept as short
as possible.
Torque limitation is activated in order to protect
the transaxle components.
When the engine is restarted (ignition switched
off for approx. 15 seconds), the transaxle is no
longer in limp home mode. There is no longer
a fault indication on the instrument cluster, and
the MIL (malfunction indicator lamp) is off.
However, the fault remains stored in the TCM.
If the fault is still present, limp home mode is
reactivated.
If limp home mode is reactivated after the
ignition is switched on, the option exists in
2008.50 Kuga 8/2011
select-shift mode to pull away in 2nd gear. This

is the case unless the transaxle is in emergency
mode 4. Only 4th gear and the reverse gear are
available in this mode.
Tasks of the electronic components
The following overview summarizes the input and
output signals from the transmission control
module.
G1163605en
Automatic
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TO MODEL INDEX
307-01-43
18
19
20
21
17
16
15
14
1
13
12
2
11
3
10
8
7
E127303
Item
Description
Item
Description
TCM
Instrument Cluster
GEM
PCM
2008.50 Kuga 8/2011
G1163605en
Automatic
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TO MODEL INDEX
307-01-44

Item
Description
Item
Description
ABS
13
Cruise control
14
15
PCM
16
Selector lever lock
17
10
18
The TSS sensor
11

(SLT)
19
The OSS sensor
20
The TFT sensor
12
21
TR sensor in TCM
Input signals
Hard wired
Item 18: ISS (input shaft speed) sensor
Supplies information on the transmission
input shaft speed. Used for calculations, for
instance the shift process, checking the
torque converter lockup and for diagnosis of
the hydraulic/mechanical operations in the
transmission.
Item 19: OSS sensor
Supplies information on the transmission
output shaft speed. Used for calculations, for
instance the vehicle speed and for diagnosis
of the hydraulic/mechanical operations in the
transmission.
Item 20: TFT sensor
Supplies information on the transmission fluid
temperature. This information is used to
adjust the shift times and the fluid pressure.
Item 21: TR sensor
Supplies the TCM with the information on the
chosen transmission range. Starting is only
possible when the selector lever is in the P
or N position. The sensor is a permanent
magnet which creates a magnetic field over
the different Hall sensors and in this way
creates a specific voltage for each shift
operation.
Via the LIN data bus
Item 7: Selector lever module (select-shift
module)
Indicates that the selector lever is locked in
position P and supplies information on the
sport mode status. Also transmits a control
signal during select-shift gear changes and
supplies information on the fault status in the
2008.50 Kuga 8/2011
selector lever module, so that the fault codes

in the module can be stored as required.
Via the CAN data bus
Item 4: PCM
Stop light switch ON/OFF, is used by the
TCC.
Coolant temperature, used for diagnosis of
the transmission temperature sensor and for
activating the catalytic converter.
Engine speed >400 rpm = engine running.
Used for starting the transmission fluid
pressure and diagnosis functions.
Engine rpm. Used for checking the torque
converter slip and the pressure build-up,
which have an effect on the shift comfort.
Kickdown. If the accelerator pedal is pressed
down and the throttle plate is wide open, the
PCM transmits a kickdown signal to the TCM.
Current engine speed, used to check the line
pressure of the transmission.
Throttle plate opening, used to calculate the
gear changes. During sport mode and
kickdown.
Accelerator pedal position, used to calculate
the shift threshold timings.
Item 5: ABS module
Supplies information on the vehicle speed
and also on the difference in speed between
the left-hand and right-hand wheels. Prevents
changing up if the speed difference is greater
than 40 km/h, to protect the differential in the
transmission.
Item 6: Vehicle speed control system
Is used to calculate the acceleration,
depending on the position of the resume and
set buttons.
G1163605en
Automatic
307-01-45

TO MODEL INDEX
307-01-45

Output signals
Hard wired
Item 8: PCM
Start inhibitor. Supplies the PCM with a signal
that indicates whether the engine can be
started or not.
module)
Controls the solenoid switch in the selector
lever unit.
Position 10: PWM solenoid valve shift
pressure (SLS)
Matches the line pressure to a shift pressure
and is activated for certain gears.
Position 11: PWM solenoid valve main line
pressure (SLT)
Adjusts the linear line pressure for gear
changes without jolts.
Position 12: PWM- solenoid valve TCC (SLU)
Matches the line pressure to a torque
converter lock-up pressure. Is also used for
certain gearshifts.
Items 13 - 17: Shift solenoids S1 S5
The TCM checks which gear is engaged as
the solenoids become active in different
patterns.
Via the LIN data bus
module)
The TCM transmits a signal to the selector
lever module which activates the LED (light
emitting diode) in the selector mechanism
assembly according to the selector lever
position.
Via the CAN data bus

Item 2: GEM
The selector lever module transmits a signal
via the TCM, which indicates that the selector
lever is locked in position P. The GEM uses
this information to control the ignition switch
key inhibit function.
The TCM transmits a signal via the GEM to
activate the back-up lamps.
Item 3: Instrument Cluster
Current selector lever position. Used to
indicate the selector lever position in the
instrument cluster.
Check the warning lamps via the GEM. In
the event of a fault, the general warning lamp
lights.
Text messages in the instrument cluster via
the GEM. The driver receives various
malfunction messages from the TCM.
The TCM transmits signals on the CAN data
bus to the PCM so that the MIL lights up in
the event of emissions-related faults.
Item 4: PCM
Transmission fluid temperature, used to
compensate for increased loads at low fluid
temperatures.
Gear selected, used by the engine so that it
can compensate for different loads.
Torque converter lockup, used by the engine
so that it can compensate for different loads.
Next gear planned by the TCM, used by the
engine to compensate for different loads.
Requirement for a reduced engine torque
during gear shifts, the engine reduces the
engine torque during gear shifts.
Torque limiting requirement, the engine limits
the engine torque according to the gear
engaged.
Item 5: ABS module
Current gear, used to transmit a signal, not
for shift control.
Vehicle speed, used as reserve.
Control valve assembly
2008.50 Kuga 8/2011
G1163605en
Automatic
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TO MODEL INDEX
307-01-46

1
2
3
4
8
E125595
Item
Description
Item

(SLT)
Shift solenoid S3
Shift solenoid S1
Shift solenoid S5
Shift solenoid S2
Shift solenoid S4
The hydraulic pressure is distributed to the

individual clutches and brakes in the valve body.
The hydraulic paths and the hydraulic pressure are
controlled electronically via three PWM solenoid
valves and five shift solenoid valves.
The shift solenoid valves S1-S5 are either in the
'open' or 'closed' state.
The control valves (SLT and SLS) regulate the
hydraulic pressure in accordance with the duty
cycle of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes.
2008.50 Kuga 8/2011
Description
The control valve (SLU) regulates the hydraulic

pressure in accordance with the duty cycle of the
electrical PWM signal. It controls the torque
converter clutch. The PWM control achieves
smooth engagement of the gears.
The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, the gears are shifted and
the torque converter lockup is activated at low
engines speeds in order to reduce the fuel
consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163605en
Automatic
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TO MODEL INDEX
307-01-47

Function of the shift solenoid valves in the gears and when shifting gears
Gear
S1
S2
S3
S4
S5
Park
R (V<=7)
R (V>7)
1<=>2
2<=>3
3<=>4
4<=>5
V = Road speed in km/h
0 = Actuated
= Not actuated
x<=>x = Gear change "up/down"
Shift solenoids S1 - S5
Item
Description
Shift solenoid S5
Shift solenoid S2
Shift solenoids S1, S2, S3, S4 and S5 are located

in the control valve assembly on the front of the
transmission.
5
1
2
3
Function
The shift solenoid valves are actuated by the TCM
TCM. The shift solenoid valves S1 and S4 are fully
open when de-energized. The shift solenoid valves
S2, S3, and S5 are fully closed when de-energized.
They control gearshifting, while the TCM decides
which gear should be engaged by activating the
shift solenoid valves in different combinations.
Consequences of signal failure
E112324
Item
Description
Shift solenoid S1
Shift solenoid S4
Shift solenoid S3
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-48

TO MODEL INDEX
307-01-48

Item
Description
Shift solenoid S1
Shift solenoid S2
Shift solenoid S3
Shift solenoid S4
Shift solenoid S5
TCM connector 'C'
If a shift solenoid valve fails, the MIL is activated

and the vehicle can be driven in the appropriate
emergency mode.
E125820
Failure of the shift solenoids

Component
Shift solenoid S1
Reason
Short B+ / open circuit
MIL
On
Short BShift solenoid S2
On
Emergency Mode 1
No 1st or 5th gear
On
Emergency Mode 1
No 1st gear / no N-D
control
Emergency function
Emergency Mode 2
Emergency Mode 4
On
Emergency Mode 1
On
Emergency Mode 1

Short B-
2008.50 Kuga 8/2011
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Automatic
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TO MODEL INDEX
307-01-49

Item
Description
Hydraulic pressure
Average current (A)
The valve actuates the torque converter clutch as

well as the reverse gear brake (B3) and 2nd - 5th
gear brake (B2). The PWM control achieves
smooth engagement of the gears. The two brakes
are actuated in 1st and 2nd gear to guarantee
engine braking.
The valve also actuates the torque converter in
such a way that is works in three positions: 'open',
'controlled looping (slip lock-up mode)', and 'locked
(full lock-up mode)'. The hydraulic function of the
valve is linear.
E112325
Installation position
The PWM solenoid valve for the TCC (SLU) is
located in the valve body on the front of the
transaxle.
Function
In lockup mode the TCC is closed. The impeller

and the turbine of the torque converter are friction
locked. The engine torque acts directly on the
transmission input shaft. Fuel consumption is
reduced due to a reduction in the torque converter
pump losses.
In slip lock-up mode, slip in the TCC is permitted
in order to improve driving comfort. The hydraulic
pressure acting on the TCM varies in accordance
with the duty signal of the actuation signal
generated by the PWM for the TCC solenoid valve
for the TCC (SLU). The temperature of the
transmission fluid increases in slip mode.
0.2
0.4
0.6
0.8
1.0
2
E125965
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-50

TO MODEL INDEX
307-01-50

E112326
2
E125966
Item
The PWM solenoid valve for shift pressure (SLS)

is located in the valve body on the front of the
transaxle.
Function
Description
TCM connector 'C'
If the PWM solenoid valve for the TCC (SLU) fails,

the MIL is activated and the vehicle can be driven
in emergency mode 1.
0.2
0.4
0.6
0.8
1.0
2
E125990
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-51

TO MODEL INDEX
307-01-51

Item
Description
Hydraulic pressure
Average current (A)
The valve directly actuates the multi-plate brake

(B1) in 2nd - 4th gear as well as the clutch (C2) in
5th and reverse gear. The PWM control achieves
smooth engagement of the gears.
If the PWM solenoid valve for shift pressure (SLS)

fails, the MIL is activated and the vehicle can be
driven in emergency mode 3.

(SLT)
The hydraulic function of the valve is linear. The

hydraulic valve is controlled by means of the
varying current resulting from the current duty
cycle. The system pressure is low with a high duty
cycle, i.e. with high current intensity (approx. 1 A),
and vice versa.
E112327
The PWM solenoid valve main line pressure
(SLT) is located in the control valve assembly on
the front of the transmission.
Function
2
E125991
Item
Description
TCM connector 'C'
The shift pressure increases to the maximum value

in the event of interruptions, which leads to hard
gearshifts when shifting to another gear. The valve
is then fully open.
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-52

TO MODEL INDEX
307-01-52
0.2
0.4
0.6
0.8
1.0
2
E125990
2
E125992
Item
Description
Hydraulic pressure
Average current (A)
The PWM solenoid valve for main line pressure

(SLT) is actuated proportionally by the TCM.
The TCM evaluates the accelerator pedal position
and the current engine torque.
The main line pressure is adapted proportionally
by the TCM via the PWM solenoid valve. This
measure enables judder-free gearshifts.
The PWM solenoid valve is open when
de-energized. In the case of faults and failure of
the control system, the PWM solenoid valve
remains fully open. The maximum main line
pressure is applied.
Item
Description

(SLT)
TCM connector 'C'
The system pressure increases to the maximum

value in the event of interruptions, which leads to
hard gearshifts when shifting to another gear. The
valve is then fully open.
If the PWM solenoid valve main line pressure
(SLT) fails, the MIL is activated and the vehicle can
be driven in emergency mode 1.
TCC
The TCC is an integral component of the torque
converter.
Operation
The TCM controls the PWM via the TCC solenoid
valve for the TCC (SLU). Based on the signals for
engine speed and accelerator pedal position as
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-53

TO MODEL INDEX
307-01-53

well as vehicle speed, driving comfort is improved
by linear actuation of the TCC.
Selector lever with integrated select-shift

switch module
The selector lever unit is located in the central

console. It is mechanically connected to the
transmission by a selector cable which moves the
gear selector shaft in the TR sensor.
The following components are integrated in the
selector lever assembly:
Selector lever lock solenoid.
Switch contact for selector lever position 'P'
LED for the selector lever position display
The selector lever has the following positions:
P: Park position
R: Reverse gear.
N: Neutral position
D: Automatically shift between all gears
S: Sport and select-shift mode (manual gear
changing)
If the selector lever is not in the 'P' position when
the vehicle is exited, a signal is transmitted to the
instrument cluster via the switch contact for selector
lever position 'P'. When the driver door is opened,
a message to move the selector lever to the 'P'
position appears in the instrument cluster and the
warning buzzer sounds. The vehicle cannot be
electrically locked if the selector lever is not moved
to the 'P' position.
E112332
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-54

TO MODEL INDEX
307-01-54

Overview of the select-shift switch module
E112331
The select-shift switch module is located on the

upper trim of the selector lever unit. The module
is supplied with power by the TCM.
Oil pump
It uses the LIN databus to interact with the TCM,

for instance to activate the selector lever position
display.
It allows the automatic transmission gears to be

changed up and down manually via the signals of
the Hall sensors.
The select-shift switch module detects the selector

lever position 'P' and 'S' via the integrated selector
lever position sensors (Hall sensors).
A cable leading from the TCM passes directly to
the select-shift switch module and is used to control
the solenoid of the selector lever lock. The
switching solenoid receives its voltage supply
directly from the module.
In the event of a fault, a signal is transmitted to the
TCM where all DTCs are stored.
5
E68097
Item
2008.50 Kuga 8/2011
Description
Fluid pump rotor, outer
Fluid pump rotor, inner
G1163605en
Automatic
307-01-55

TO MODEL INDEX
307-01-55

Item
The torque converter transmits the output torque

hydraulically from the engine to the transaxle input
shaft.
Description
Drive
Intake side
Delivery side
The fluid pump operates on the principle of a

G-rotor fluid pump.
The fluid pump draws transmission fluid from the
fluid pan, builds up fluid pressure and then supplies
it to the valve body.
The fluid pump is driven by the crankshaft via the
torque converter housing.
The stator increases the torque up to the clutch

take-up point. At the clutch take-up point, the speed
difference between impeller and turbine is
approximately 90 %.
In order to improve the efficiency, the torque
converter features a hydraulically-activated TCC.
When the TCC is engaged, the torque is
transmitted directly from the crankshaft via the
torque converter housing to the transaxle input
shaft.
The TCC is an integral component of the torque
converter.
Torque converter with TCC
Function
1
The TCM controls the PWM via the TCC solenoid

valve for the TCC (SLU). Based on the signals for
engine speed and accelerator pedal position as
well as vehicle speed, driving comfort is improved
by linear actuation of the TCC.
A
B
E89081
Item
E66428
Item
Description
Torque converter housing and impeller
Turbine
TCC
Transaxle input shaft
Stator with roller-type one-way clutch
2008.50 Kuga 8/2011
Description
APP (accelerator pedal position)
Vehicle speed
TCC disengaged
Slip lock-up mode
Full lock-up mode
Full lock-up mode

In lockup mode the TCC is closed. The impeller
and the turbine of the torque converter are friction
locked. The engine torque acts directly on the
transmission input shaft. Fuel consumption is
reduced due to a reduction in the torque converter
pump losses.
G1163605en
Automatic
307-01-56

TO MODEL INDEX
307-01-56

Full lock-up mode of the TCC is not generated at
engine temperatures below 20 C (68 F).
Slip lock-up mode
In slip lock-up mode, slip in the TCC is permitted
in order to improve driving comfort. The hydraulic
pressure acting on the TCM varies in accordance
with the duty signal of the actuation signal
generated by the PWM for the TCC solenoid valve
for the TCC (SLU). The automatic transaxle
temperature increases in slip lock-up mode.
The TSS sensor
2
E89083
E112328
The TSS sensor is mounted at the top of the

transmission housing. It is an active sensor and is
supplied with 12 V.
Function
Item
Description
Signal voltage
Signal frequency
Transmission input shaft speed
The TSS sensor is a Hall sensor. It generates a

square-wave signal, the frequency of which varies
depending upon the speed of the transmission
input shaft.
The frequency of the square-wave signal increases
with the transmission input shaft speed. The TSS
sensor picks up the speed at the housing of the
1st - 5th gear clutch (C1).
The TCM uses the information from the TSS sensor
to determine the following parameters:
Calculation of the torque reduction that needs
to be requested by the PCM during shifting.
Comparison of engine speed with transmission
input shaft speed for calculation of torque
converter slip.
Calculation of the shift points.
Calculation of the engaging and disengaging
point for the TCC (lock-up function).
Calculation of the current gear ratios by
comparison of the OSS sensor signal.
2008.50 Kuga 8/2011
G1163605en
Automatic
307-01-57

TO MODEL INDEX
307-01-57

The OSS sensor
E112329
The OSS sensor is located at the rear of the

transmission casing. It supplies signals about the
transaxle output speed to the TCM.
Function
4
1
2
E125799
Item
Description
The TSS sensor
TCM connector 'B'
Emergency mode 1
Torque limitation is activated in order to protect
the transaxle components from damage.
The engine speed serves as a substitute value.
the MIL is off. However, the fault remains stored
in the TCM. If the fault is still present, limp home
mode is reactivated.
2
E89083
Item
Description
Signal voltage
Signal frequency
Transmission input shaft speed
The OSS sensor is a Hall sensor. The OSS sensor

generates a square-wave signal, the frequency of
which varies depending upon the speed of the
2008.50 Kuga 8/2011
G1163605en
Automatic
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TO MODEL INDEX
307-01-58

transaxle output shaft. The frequency of the
square-wave signal increases with the speed of
the transmission output shaft.
The OSS sensor picks up the speed at the gear of
the parking lock.
The TCM uses the information from the OSS
sensor for the following parameters:
Calculation of the degree of torque reduction
that needs to be requested by the PCM during
shifting.
Calculation of the shift points.
Calculation of the engaging and disengaging
point for the TCC (lock-up function).
Calculation of the current gear ratios by
comparison of the TSS sensor signal.
The torque converter lockup and adaptation

functions are deactivated.
The wheel speed signal is transmitted by the
ABS to the TCM via the HS-CAN data bus. This
signal serves as a substitute value.
The TFT sensor
E125802
2
E125800
Item
Description
The OSS sensor
TCM connector 'B'
2008.50 Kuga 8/2011
The TFT sensor is located in the valve body and

is an integral component of the internal transaxle
wiring harness.
Function
G1163605en
Automatic
307-01-59

TO MODEL INDEX
307-01-59

1
10000
100
1
50
150
E89089
Item
Description
Resistance (Ohms)
Temperature (C)
The sensor is an NTC (negative temperature

coefficient) (negative temperature coefficient)
sensor. The voltage supply is 5 V. The transmission
fluid temperature is detected by measuring the
voltage drop across the NTC resistor.
The TCM uses the transmission fluid temperature

information for the following calculations:
Transaxle shift points
If the transmission fluid temperatures are too
high, slip lock-up of the TCC is prevented.
2
E125803
Item
Description
The TFT sensor
TCM connector 'C'
No activation of TCC slip lock-up mode.

No activation of TCC full lock-up mode.
The MIL is activated.
If the sensor fails, a temperature substitute value
of 30 C (86 F) is initially assumed. After 15
minutes driving, the substitute value is raised
to 111 C.
2008.50 Kuga 8/2011
G1163605en
Automatic

TO MODEL INDEX
307-01-60
307-01-60

The TR sensor
E125819
The TR sensor and the TCM form one unit. This

unit is located at the top of the transmission casing,
on the gear linkage.
Function
The TR sensor has three separate functions:
Transmit a signal to the TCM about the selected
transmission range.
To transmit the signal to switch on the reversing
lamps to the GEM when the selector lever is in
the 'R' position.
To transmit the start enable signal to the PCM
when the selector lever is in the 'P' or 'N'
position.
The TR sensor contains a permanent magnet and
a linear Hall detector. It produces a signal voltage
between 0 and 5 V. This signal voltage
corresponds to the selector lever position currently
chosen.
Voltage values for the different gears:
P approximately 0.65 V
R approximately 1.64 V
N approximately 2.12 V
D approximately 2.49 V
If the TR sensor fails, the MIL is activated and the
vehicle can be driven in emergency mode 4. The
vehicle can no longer be started for safety reasons
after the ignition is switched off because the TCM
does not detect the current transmission range.
If a shift solenoid valve fails, the MIL is activated
and the vehicle can be driven in the appropriate
emergency mode.
2008.50 Kuga 8/2011
G1163605en
Automatic

TO MODEL INDEX
307-01-61
307-01-61
GENERAL PROCEDURES
Transmission Fluid Level Check

General Equipment
6.
Materials
Name
Specification
Automatic Transmission WSS-M2C924-A / 4U7JOil E-AW

M2C924-AA
Inspection
Operation).
2. Connect the Ford diagnostic equipment.
3. Make sure that the transmission is not in
emergency operation mode.
4. Make sure that the transmission fluid
temperature is between 70 and 80C.
80
E114668
70
7. NOTE: Make sure that the selector lever and

the gearshift mechanism are in the park (P)
position.
E114667
5.
9.
WARNING: Make sure that the brake

pedal and parking brake are fully applied
during the test.
Start and run the engine at idle.
E98183
2008.50 Kuga 8/2011
G1163606en
Automatic
307-01-62

TO MODEL INDEX
307-01-62
GENERAL PROCEDURES
10.
13.
E114670
11.
E114938
CAUTION: Use lint free cloth.
14.
80
70
E98183
E114671
12. Adjust the fluid level in the automatic

transmission if necessary.
Material: Automatic Transmission Oil E-AW
(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid

16. Disconnect the Ford diagnostic equipment.
E114672
2008.50 Kuga 8/2011
G1163606en
Automatic
307-01-63

TO MODEL INDEX
307-01-63
GENERAL PROCEDURES
Transmission Fluid Drain and Refill

21. Torque: 40 Nm
General Equipment
Fluid Container
Materials
Name
Specification

M2C924-AA
Draining
Operation).
E114758
Filling
22.
19.
E114670
E98183
23. Use a suitable plastic tube.

20.

escaping fluid.
E114758
E114933
2008.50 Kuga 8/2011
G1163607en
Automatic
307-01-64

TO MODEL INDEX
307-01-64
GENERAL PROCEDURES
24.

are sealed.
27. Material: Automatic Transmission Oil E-AW

(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid
2l
E114759
25.
E114762
28. NOTE: Make sure that the selector lever and

the gearshift mechanism are in the park (P)
position.
29. Start and run the engine at idle.
E114760
26.
30. Switch off the engine, if bubbles are visible in

the clear plastic tube.

damage the seal.
Use a suitable clear plastic tube.
E114807
E114761
2008.50 Kuga 8/2011
G1163607en
Automatic
307-01-65

TO MODEL INDEX
307-01-65
GENERAL PROCEDURES
(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid

(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid
2l
E114762
E114992
36.
33. Switch off the engine, if bubbles are visible in

the clear plastic tube.
E114993
E114807

38.
CAUTION: Use lint free cloth.
34.
30
20
E114759
E114934
2008.50 Kuga 8/2011
G1163607en
Automatic
307-01-66

TO MODEL INDEX
307-01-66
GENERAL PROCEDURES
40. Refer to: Transmission Fluid Level Check
(307-01 Automatic Transmission/Transaxle Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD, General Procedures).
2008.50 Kuga 8/2011
G1163607en
Automatic
307-01-67

TO MODEL INDEX
307-01-67
Halfshaft Seal LH
Special Tool(s)
Special Tool(s)
308-203
Installer, Differential Double
Lip Seal
303-293
16066
21143
Removal
Operation).
2. Refer to: Front Halfshaft LH (205-04 Front Drive

303-293
E114366
Installation
308-203
E114367
2008.50 Kuga 8/2011
G1163610en
Automatic
307-01-68

TO MODEL INDEX
307-01-68
Halfshaft Seal RH
308-784
Installer, Halfshaft Seal

E115803
Removal
Operation).
Installation
2. Refer to: Transfer Case (307-07 Transfer Case

- Vehicles With: 5-Speed Automatic Transaxle
- 6DCT450, Removal).
308-784
E114369

- 6DCT450, Installation).
3. Refer to: Transfer Case Fluid Level Check
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle 6DCT450, General Procedures).
E114368
2008.50 Kuga 8/2011
G1183024en
Automatic
307-01-69

TO MODEL INDEX
307-01-69
Main Control Valve Body

Removal
NOTE: Note the different lengths of the bolts.
1. Refer to: Transmission Fluid Pan (307-01

Automatic Transmission/Transaxle - Vehicles
With: 5-Speed Automatic Transaxle - AW55
AWD, Removal and Installation).
2. NOTE: Note the position of the electrical
connectors.
x2
E115691
4.
E115690
3.
CAUTION: Make sure that no component

falls off during removal.
E115692
2008.50 Kuga 8/2011
G1163642en
Automatic
307-01-70

TO MODEL INDEX
307-01-70

Installation
3. Torque: 10 Nm
1. NOTE: Use new seals.
4
7
1
2
E115692
2.

NOTE: Make sure that the selector lever is in

the neutral (N) position.
NOTE: Use a new seal.
NOTE: Only tighten the bolts finger tight at this
stage.
E115693
x2
E115691
2008.50 Kuga 8/2011
G1163642en
Automatic
307-01-71

TO MODEL INDEX
307-01-71

4.

Torque: 10 Nm
E115690
5. Refer to: Transmission Fluid Pan (307-01

Automatic Transmission/Transaxle - Vehicles
With: 5-Speed Automatic Transaxle - AW55
AWD, Removal and Installation).
2008.50 Kuga 8/2011
G1163642en
Automatic
307-01-72

TO MODEL INDEX
307-01-72
Output Shaft Speed (OSS) Sensor

Materials
Name
Specification

M2C924-AA
Removal
Operation).
2.
Installation
installed.

escaping fluid.

(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid
E115345
E115336
3.
2.
WARNING: Make sure that a new bolt is

installed.
Torque: 5 Nm
E115335
E115253
2008.50 Kuga 8/2011
G1163635en
Automatic
307-01-73

TO MODEL INDEX
307-01-73
Torque Converter Seal

303-293

308-095
Installer, Input Shaft Bearing
16038
21143

Materials
Name
Specification

M2C924-AA
Removal
Removal).
2.
303-293
E115423
2008.50 Kuga 8/2011
E115424
G1163637en
Automatic
307-01-74

TO MODEL INDEX
307-01-74

Installation
Make sure that the specified installation

depth is achieved.
General Equipment: Round-Ended Steel Rule
308-095
E115425

(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid
14
E115422

Installation).
E115465
3. CAUTIONS:
Take extra care not to damage the seal.
2008.50 Kuga 8/2011
G1163637en
Automatic

TO MODEL INDEX
307-01-75
307-01-75
Transmission Fluid Pan

Special Tool(s)
Materials
303-428
Separator, Oil Pan
Name
Specification
Silicone Sealant LG
WSS-M4G320-A3 /
6G9N-M4G320-AA
21179
Removal
4. 2. Special Tool(s): 303-428
1.
x9
E115314

2
3.
303-428
E115341
E115327
2008.50 Kuga 8/2011
G1163608en
Automatic
307-01-76

TO MODEL INDEX
307-01-76

Installation
1.
3.

material.
Material: Silicone Sealant LG (WSS-M4G320-A3
/ 6G9N-M4G320-AA) sealant
E115327
3mm
4.
E115316
2. Torque: 18 Nm
x9
E115314
5. Refer to: Transmission Fluid Drain and Refill

E115315
2008.50 Kuga 8/2011
G1163608en
Automatic
307-01-77

TO MODEL INDEX
307-01-77
Transmission Range (TR) Sensor

Special Tool(s)
501-028A
Pliers, Door Trim Removal
43001A
Removal
3.
1.
E114413
2.
E114505
4.
20 mm
E114506
E114504
2008.50 Kuga 8/2011
G1163634en
Automatic
307-01-78

TO MODEL INDEX
307-01-78

5.
7. 1.
CAUTION: Use an open-ended

wrench to prevent the component
from turning.
3. Special Tool(s): 501-028A
E114436
6.
501-028A
E114438
8.
E114437
x3
E114439
2008.50 Kuga 8/2011
G1163634en
Automatic
307-01-79

TO MODEL INDEX
307-01-79

Installation
3. 2.

installed.
CAUTION: Use an open-ended

wrench to prevent the component
from turning.
3. Torque: 25 Nm
2. NOTE: Only tighten the bolts finger tight at

this stage.
3
E114441
2. 2. Torque: 16 Nm
E114442
4.
1
E114440
E114437
2008.50 Kuga 8/2011
G1163634en
Automatic
307-01-80

TO MODEL INDEX
307-01-80

5. Refer to: Selector Lever Cable Adjustment Vehicles With: 5-Speed Automatic Transaxle
7.
E114505
8.
E114436
6.
E114507
2008.50 Kuga 8/2011
E114504
G1163634en
Automatic
307-01-81

TO MODEL INDEX
307-01-81
Turbine Shaft Speed (TSS) Sensor

Materials
Name
Specification

M2C924-AA
Removal
Operation).
Installation
installed.
2.

(WSS-M2C924-A / 4U7J-M2C924-AA)
transmission fluid
E115344
E115336
3.
2.
WARNING: Make sure that a new bolt is

installed.
Torque: 5 Nm
E115335
E115252
2008.50 Kuga 8/2011
G1163632en
Automatic
307-01-82

TO MODEL INDEX
307-01-82
REMOVAL
Transmission
Removal
303-290-01
Adapter for 303-290A

303-290A
Support Bar, Engine
303290A
2114001
303-290A-14
303-290-03A
303290A14
30329003A
Cable Ties
303-290-05A
30329005A
Transmission Jack
Wooden Block
Operation).
3.
E114689
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-83

TO MODEL INDEX
307-01-83
REMOVAL
4. On both sides.
Loosen: 3 turn(s)

Installation).
x3

stage.
E99147

6.
E114727
9.
E101006
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-84

TO MODEL INDEX
307-01-84
REMOVAL
x4
E114605
10.
11.
x2
E114606
E114436
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-85

TO MODEL INDEX
307-01-85
REMOVAL
12.
15.
E114728
E114611
13.
16.
E114609
14.
E114612
17.
1
E114610
x2
E114613
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-86

TO MODEL INDEX
307-01-86
REMOVAL
18.
22.
x2
x6
E114614
x2

20.
E114731
23.
E114618
E114617
24.

x2
E114619
E98634
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-87

TO MODEL INDEX
307-01-87
REMOVAL
and Installation).
26. 1. NOTE: Note the position of the component
before removal.
x6
28.
20 mm
x3
2
1
E101018
E101022
27.
29.
x3
x4
1
E101021
x2
3
E115557
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-88

TO MODEL INDEX
307-01-88
REMOVAL
31. Install the Special Tool(s): 303-290-01,

303-290-03A, 303-290-05A, 303-290A,
303-290A-14
303-290A-14
303-290-01
303-290-03A
303-290-05A
303-290A
303-290-01
E114725
33.
32.
x2
E114608
E114607
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-89

TO MODEL INDEX
307-01-89
REMOVAL
303-290A
E114726

36.
37.

are sealed.
x2
E114620
E114624
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-90

TO MODEL INDEX
307-01-90
REMOVAL
38.
41.
x2
E114622

1. General Equipment: Wooden Block
E114623
42.

another technician.
E114733
40.
x2
E114734
E114621
2008.50 Kuga 8/2011
G1163644en
Automatic
307-01-91

TO MODEL INDEX
307-01-91
INSTALLATION
Transmission
Installation
303-290-01
Materials
Name
Grease K-HT
ESD-M1C220-A /
A88SX1C220AA
Grease KS-PS
2114001
303-290-03A
Specification

Operation).
30329003A
303-290-05A
30329005A
303-290A
Support Bar, Engine
303290A
303-290A-14
14
303290A14
E114801
Cable Ties
Transmission Jack
Wooden Block
2008.50 Kuga 8/2011
4.

another technician.
CAUTIONS:
Make sure that the locating dowels
remain installed.
G1163646en
Automatic
307-01-92

TO MODEL INDEX
307-01-92
INSTALLATION
Make sure that the torque converter
remains in the transmission.
6. Torque: 48 Nm
E114621
x2
E114751
5. Perform this and the following operation

simultaneously.
Torque: 48 Nm

1. General Equipment: Wooden Block
x2
E114733
E114623
8. Torque: 48 Nm
E114622
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-93

TO MODEL INDEX
307-01-93
INSTALLATION
9. Torque: 48 Nm
10. Torque: 6 Nm
x2
E114620
E114624

303-290A
E114730
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-94

TO MODEL INDEX
307-01-94
INSTALLATION
13. Torque: 80 Nm
x2
E114608
303-290A
E114730
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-95

TO MODEL INDEX
307-01-95
INSTALLATION
15.
17. Remove the Special Tool(s): 303-290-01,

303-290-03A, 303-290-05A, 303-290A,
303-290A-14
19. Material: Grease K-HT (ESD-M1C220-A /
A88SX1C220AA) grease
E114729
16. 1. Torque: 148 Nm

2. Torque: 10 Nm
E114591
20. 1.
2.
3.
4.
Torque: 60 Nm
Torque: 60 Nm
Torque: 25 Nm
Torque: 9 Nm
1
2
4
E114607
E115556
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-96

TO MODEL INDEX
307-01-96
INSTALLATION
21.
23. 1.
20 mm

Torque: 35 Nm
2. Torque: 35 Nm
3. Torque: 35 Nm
2
1
x3
x2
1
2
E101042
E101044
22. Torque: 25 Nm

2. Torque: 80 Nm
E101021
2008.50 Kuga 8/2011
E114913
G1163646en
Automatic
307-01-97

TO MODEL INDEX
307-01-97
INSTALLATION
26. 1. Material: Grease KS-PS (SA-M1C9107-A /
installed.
28. Torque: 10 Nm
3. Torque: 48 Nm
x2
1
E114617
x2
E114732


final tightening.
Torque: 60 Nm
4
1
E98634
x6
E124910
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-98

TO MODEL INDEX
307-01-98
INSTALLATION
31. Torque: 40 Nm
2. Torque: 9 Nm
x2
1
E114610
35. Torque: 25 Nm
E114616
32. Torque: 25 Nm
E114609
36.
E114612
33.
E114728
E114611
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-99

TO MODEL INDEX
307-01-99
INSTALLATION
37. Torque: 25 Nm
x2
E114606
E114436
2. Torque: 25 Nm
3. Torque: 10 Nm
2
1
x4
E114615
2008.50 Kuga 8/2011
G1163646en
Automatic
307-01-100

TO MODEL INDEX
307-01-100
INSTALLATION
40. Torque: 10 Nm

42. On both sides.
Torque: 35 Nm
x3
E99147
E101006

Installation).
44.
E114689

Refer to: Transmission Fluid Level Check
2008.50 Kuga 8/2011
G1163646en
307-02-1

TO MODEL INDEX
Transmission/Transaxle Cooling Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
307-02-1
SECTION 307-02 Transmission/Transaxle Cooling

Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450

CONTENTS
PAGE

Transmission Cooling (Component Location).....................................................................
Transmission Cooling (Overview).......................................................................................
Overview.............................................................................................................................
307-02-2
307-02-3
307-02-3

Transmission Fluid Cooler Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD.
Transmission Fluid Cooler Tubes Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD..................................................................................................................................
307-02-4
307-02-8

TO MODEL INDEX
307-02-2
307-02-2
Transmission Cooling Component Location

1
4
E112583
Item
Description
The transmission fluid cooler.
Push connect fittings
2008.50 Kuga 8/2011
Item
Description
From transmission fluid cooler to

transmission
From transmission to transmission fluid

cooler
G1163663en
307-02-3

TO MODEL INDEX
307-02-3
Transmission Cooling Overview

Overview
The transmission fluid cooler is secured on the
radiator.
The transmission fluid cooler operates according
to the heat exchanger principle. The ram air
passing through the radiator withdraws heat from
the transmission fluid.
2008.50 Kuga 8/2011
G1163664en

TO MODEL INDEX
307-02-4
307-02-4
Transmission Fluid Cooler Vehicles With: 5-Speed Automatic

Transaxle - AW55 AWD
Removal
4. 2. If equipped.

Operation).
x2
2.
x4
E114920
E114921
5.
3.
x4
E114919
2008.50 Kuga 8/2011
G1163667en
307-02-5

TO MODEL INDEX
307-02-5
30 mm
E114924
6.

are sealed.

8.
E98183
9.
E114922
E98184
2008.50 Kuga 8/2011
G1163667en
307-02-6

TO MODEL INDEX
307-02-6

10.

are sealed.
11. Torque: 15 Nm
E114918
12.
E114923
E114926
Installation
2.
E114925
2008.50 Kuga 8/2011
G1163667en
307-02-7

TO MODEL INDEX
307-02-7

2008.50 Kuga 8/2011
G1163667en

TO MODEL INDEX
307-02-8
307-02-8
Transmission Fluid Cooler Tubes Vehicles With: 5-Speed

Automatic Transaxle - AW55 AWD
Removal
4.

are sealed.

Operation).
2.
x4
E114922

6.
E114919
3. 2. If equipped.
E98183
E114920
2008.50 Kuga 8/2011
G1163668en
307-02-9

TO MODEL INDEX
307-02-9

7.
9.

are sealed.
E98184
8.

are sealed.
E114962
Installation
E114923
2008.50 Kuga 8/2011
G1163668en

TO MODEL INDEX
Automatic Transmission/Transaxle External

Controls Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
.307-05-1
Automatic Transaxle - 6DCT450
307-05-1
SECTION 307-05 Automatic Transmission/Transaxle

External Controls Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
307-05-2

External Controls (Component Location)...........................................................................
External Controls (Overview)..............................................................................................
Transmission range selector..............................................................................................
Transmission range selector lever emergency release..................................................
307-05-3
307-05-4
307-05-4
307-05-4
GENERAL PROCEDURES
Selector Lever Cable Adjustment Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD..................................................................................................................................
307-05-6

Selector Lever Cable Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD.......
Selector Lever Assembly Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD..
307-05-7
307-05-11

TO MODEL INDEX

.307-05-2
307-05-2
SPECIFICATIONS
Information not available at this time.
2008.50 Kuga 8/2011
G1163681en

TO MODEL INDEX

.307-05-3
307-05-3
External Controls Component Location
8
7
E112582
Item
Description
Selector lever mechanism assembly
Selector lever cable guide
Selector cable
Damper weight
2008.50 Kuga 8/2011
Item
Description
Adjusting mechanism for selector lever

cable
Shift valve shaft lever
Selector lever cable bracket
Edge Clip
G1163682en

TO MODEL INDEX

.307-05-4
307-05-4
External Controls Overview

Transmission range selector
E112313
The transmission range selector is located on the

center console and is mechanically connected to
the transmission by a cable for operation of the
gear selector shaft and the TR (transmission range)
sensor.
Transmission range selector lever

emergency release
As well as the positions P/R/N/D, the transmission

range selector provides a position for the sport and
select-shift mode (S). The manual gear position
can be selected at any time while driving. The gear
selected is locked until the driver selects another
gear.
The engine can only be started in positions P or

N.
The selector cable adjustment mechanism is at the

transmission end of the selector cable.
NOTE: Details of the exact procedure and
specifications can be found in the current service
literature.
4
1
E114512
2008.50 Kuga 8/2011
G1163683en

TO MODEL INDEX

.307-05-5
307-05-5

If the release mechanism of the selector lever lock
fails when the selector lever is in the P position
through the solenoid of the selector lever lock
actuated by the TCM, it is possible to emergency
release it.
Procedure:
Carefully slide a flat screwdriver into the slot (1).
Turn the screwdriver (2).
Press the screwdriver downwards to detach the
gaiter frame from the trim panel (3).
Press the gaiter frame to move the emergency
release downwards and move the selector lever
out of position P (4).
Pull the gaiter upwards until the gaiter frame
engages in the gaiter frame.
2008.50 Kuga 8/2011
G1163683en

TO MODEL INDEX

.307-05-6
307-05-6
GENERAL PROCEDURES
Selector Lever Cable Adjustment Vehicles With: 5-Speed

4.
Adjustment
1.
E114416
E114413
2.
5. Start the engine and move the selector lever

through all the gear positions. Wait until each
gear engages when moving through the gear
positions.
6. Check that the selector lever position indicator
corresponds to the position of the selector lever,
repeat the adjustment procedure if necessary.
7.
E114414
3.
E108427
E114415
2008.50 Kuga 8/2011
G1163685en

TO MODEL INDEX

.307-05-7
307-05-7
Selector Lever Cable Vehicles With: 5-Speed Automatic

General Equipment
Knife
Removal
5.

Operation).
x2
2.
x2
x2
E100948
6.
E114436

x4
4.
x7
E114517
E98543
2008.50 Kuga 8/2011
G1163686en

TO MODEL INDEX

.307-05-8
307-05-8

7.
12.
E114513
E114519
13. Torque: 25 Nm

10.
x4
E114516
14.
E114518
11. Torque: 25 Nm
x4
x4
E100949
2008.50 Kuga 8/2011
E101415
G1163686en

TO MODEL INDEX

.307-05-9
15. Torque: 9 Nm
307-05-9
17.
x4
50
E114520
16.
E114521
E114522
18. General Equipment: Knife
E114515
19. Torque: 9 Nm
E114514
2008.50 Kuga 8/2011
G1163686en

TO MODEL INDEX

.307-05-10
307-05-10

Installation
kinked or bent.
2. 1. Torque: 25 Nm
2. Torque: 25 Nm
3. Torque: 30 Nm
4. Torque: 25 Nm
x2
x2
x2
E100960
2008.50 Kuga 8/2011
G1163686en

TO MODEL INDEX

.307-05-11
307-05-11
Selector Lever Assembly Vehicles With: 5-Speed Automatic

Removal
kinked or bent.
4.

2.
x4
E101415
5. Torque: 9 Nm
E114518
3.
x4
50
E114519
E114520
2008.50 Kuga 8/2011
G1163687en

TO MODEL INDEX

.307-05-12
307-05-12

6.
E114521
7.
E114522
Installation
kinked or bent.
1. Install all components in reverse order.
2008.50 Kuga 8/2011
G1163687en
Transfer
307-07-1

TO MODEL INDEX
Case Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07-1
SECTION 307-07 Transfer Case Vehicles With: 5-Speed Automatic Transaxle

- AW55 AWD/6-Speed Automatic Transaxle - 6DCT450

CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
307-07-2

Transfer Case (Component Location)................................................................................
Transfer Case (System Operation and Component Description).......................................
307-07-3
307-07-8
307-07-8
GENERAL PROCEDURES
Transfer Case Fluid Level Check.......................................................................................
307-07-9

Transfer Case Connecting Sleeve......................................................................................
Transfer Case Connecting Sleeve Seals Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD.....................................................................................................................
Transfer Case Rear Seal....................................................................................................
Transfer Case Seal LH.......................................................................................................
Transfer Case Seal RH.......................................................................................................
307-07-10
307-07-13
307-07-14
307-07-15
307-07-17
REMOVAL
Transfer Case.....................................................................................................................
307-07-18
INSTALLATION
Transfer Case.....................................................................................................................
307-07-19
Transfer
307-07-2

TO MODEL INDEX
307-07-2
SPECIFICATIONS
Capacities
Litres
Transmission Fluid 8U7J-19G518-BA
2008.50 Kuga 8/2011
0.45
G1164984en
Transfer
307-07-3

TO MODEL INDEX
307-07-3
Transfer Case Component Location

Powertrain overview
1
3
3
4
2
6
E102416
Item
Description
Item
Description
Transaxle with front axle differential
Drive shaft
Transfer box
Rear drive axle
Front wheel half shafts
Rear wheel half shafts
2008.50 Kuga 8/2011
G1164985en
Transfer
307-07-4

TO MODEL INDEX
307-07-4

Transfer box
E115223
Item
Description
Transfer box
Heat deflector
Bracket, transfer box to engine
2008.50 Kuga 8/2011
G1164985en
Transfer
307-07-5

TO MODEL INDEX
307-07-5

Transfer box seals
3
4
1
2
E115284
Item
Description
Item
Description
Output drive shaft flange retaining bolt
Hollow shaft seals, left
Output drive flange
Hollow shaft seals, right
Output differential pinion gear seal
2008.50 Kuga 8/2011
G1164985en
Transfer
307-07-6

TO MODEL INDEX
307-07-6

Hollow shaft seal, left
E115285
Hollow shaft seals, right
1
2
Item
Description
Item
Description
Transfer box
Locking device
Bolt
Adjustable bearing, transfer box
Oil seals
2008.50 Kuga 8/2011
G1164985en
Transfer
307-07-7

TO MODEL INDEX
307-07-7

Differential/drive - transfer box
4
5
E102901
Item
Description
Item
Description
Taper roller bearing - differential
Drive teeth - transfer box
Differential case
Differential pinion gears
Spur gear
2008.50 Kuga 8/2011
G1164985en
Transfer
307-07-8

TO MODEL INDEX
307-07-8
Transfer Case System Operation and Component Description

System Operation
2
E103728
Item
Description
Hollow shaft
Output shaft
Output drive flange
NOTE: From the start of series production, the

transfer box will be subject to a "Black Box Phase"
and will therefore not be repaired.
To realise the all-wheel drive, a transfer box has
been flange-mounted to the manual transaxle. The
transfer box is designed as an angular gear to
transfer the torque from the transaxle to the rear
axle. The hollow shaft of the transfer box is inserted
in a tooth on the gear case. From the hollow shaft,
torque is transferred to the driveshaft through the
output shaft/output flange via crown gear and
differential pinion gear.
2008.50 Kuga 8/2011
G1164987en
Transfer
307-07-9

TO MODEL INDEX
307-07-9
GENERAL PROCEDURES
Transfer Case Fluid Level Check

Materials
Name
Specification
Rear Axle Oil SAE 75W- 8U7J-19G518-BA

90
3. Material: Rear Axle Oil SAE 75W-90

(8U7J-19G518-BA) transmission fluid
Correct the rear axle oil level if neccessary.
20 ml ~ 1 mm
Inspection
Operation).
2.
0 mm
E114595
E139436

installed.
Torque: 34 Nm
E139434
2008.50 Kuga 8/2011
G1164988en
Transfer
307-07-10

TO MODEL INDEX
307-07-10
Transfer Case Connecting Sleeve

308-784

308-785
E115804
E115803
Copper Hammer
Hot Air Gun
Puller
Punch
Removal
2008.50 Kuga 8/2011
G1164990en
Transfer
307-07-11

TO MODEL INDEX
307-07-11

Operation).

3. 2. General Equipment: Puller
E115597
Installation
1. General Equipment: Hot Air Gun
175
150
2
E115596
E115598
2.
General Equipment: Copper Hammer
E115599
E115627
2008.50 Kuga 8/2011
G1164990en
Transfer
307-07-12

TO MODEL INDEX
307-07-12

308-785
308-784
E114369

60

E115600
4.
E115601
2008.50 Kuga 8/2011
G1164990en
Transfer
307-07-13

TO MODEL INDEX
307-07-13
Transfer Case Connecting Sleeve Seals Vehicles With: 5-Speed

Removal
1. Refer to: Transfer Case Connecting Sleeve
AWD/6-Speed Automatic Transaxle 6DCT450, Removal and Installation).
Installation
2008.50 Kuga 8/2011
G1164991en
Transfer
307-07-14

TO MODEL INDEX
307-07-14
Transfer Case Rear Seal

Removal
1. Refer to: Transfer Case Rear Seal (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
Installation
1. Refer to: Transfer Case Rear Seal (307-07
and Installation).
2008.50 Kuga 8/2011
G1164992en
Transfer

TO MODEL INDEX
307-07-15
307-07-15
Transfer Case Seal LH

Special Tool(s)
Special Tool(s)
303-293
204-351
Installer, Pivot Bushing
21143
E45281
308-788
Protector, Transfer Case Seal
E115807
Removal
2008.50 Kuga 8/2011
G1164993en
Transfer
307-07-16

TO MODEL INDEX
307-07-16

Operation).
Refer to: Transfer Case (307-07 Transfer Case
Installation
1. 1. Install the Special Tool(s): 308-788
204-351/2
3

204-351/1
303-293
3
308-788
2
1
E115697
E115696
2008.50 Kuga 8/2011

Refer to: Transfer Case Fluid Level Check
G1164993en
Transfer
307-07-17

TO MODEL INDEX
307-07-17
Transfer Case Seal RH

Removal
1. Refer to: Transfer Case Seal RH (307-07
and Installation).
Installation
1. Refer to: Transfer Case Seal RH (307-07
and Installation).
2008.50 Kuga 8/2011
G1164994en
Transfer
307-07-18

TO MODEL INDEX
307-07-18
REMOVAL
Transfer Case
Removal
2008.50 Kuga 8/2011
G1164996en
Transfer
307-07-19

TO MODEL INDEX
307-07-19
INSTALLATION
Transfer Case
Installation
2008.50 Kuga 8/2011
G1164998en

TO MODEL INDEX
309-00-1
Exhaust System 2.5L Duratec (147kW/200PS) - VI5
309-00-1
SECTION 309-00 Exhaust System 2.5L Duratec (147kW/200PS) - VI5

CONTENTS
PAGE

Exhaust System (Component Location).............................................................................
309-00-2

Exhaust Flexible Pipe.........................................................................................................
Catalytic Converter.............................................................................................................
309-00-3
309-00-6

TO MODEL INDEX
309-00-2
309-00-2
Exhaust System Component Location
1
2
E106894
Item
Description
Item
Description
Exhaust flexible pipe gasket
Exhaust catalytic convertor
HO2S (heated oxygen sensor)
Rear gasket, catalytic converter
Exhaust flexible pipe
Rear Muffler
Front gasket, catalytic converter
2008.50 Kuga 8/2011
G1079149en

TO MODEL INDEX
309-00-3
309-00-3
Exhaust Flexible Pipe

General Equipment
Cable Ties
Materials
Name
Specification
Grease KS-PS
Removal
3. Torque: 20 Nm
1.
4
2
E65070
2.

residue.
1. Torque: 10 Nm
2. Torque: 4 Nm
3. Torque: 10 Nm
E112607
4.
1
3
1
2
E68504
E67948
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
2008.50 Kuga 8/2011
G1079152en

TO MODEL INDEX
309-00-4
309-00-4

Make sure that the exhaust flexible pipe
is not forcibly bent.
2. Torque: 47 Nm
3. Torque: 28 Nm
9.
x3
E66050
10. Torque: 30 Nm
E112609

7.
E65299
E112254
TIE0014991
2008.50 Kuga 8/2011
G1079152en

TO MODEL INDEX
309-00-5
309-00-5

Torque: 48 Nm
x2
11.
E112253
12. Material: Grease KS-PS (SA-M1C9107-A /

Torque: 48 Nm
E112608
Installation
2008.50 Kuga 8/2011
G1079152en

TO MODEL INDEX
309-00-6
309-00-6
Catalytic Converter
General Equipment
Cable Ties
Materials
Name
Grease KS-PS
Specification
Removal
4.

2.
E66050
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
E65299
Make sure that the exhaust flexible pipe

is not forcibly bent.
x2

Torque: 50 Nm
TIE0014991
E66052
2008.50 Kuga 8/2011
G1079153en

TO MODEL INDEX
309-00-7
309-00-7

6.

x2

Torque: 50 Nm
E112253
7. NOTE: This step is not necessary when

Torque: 45 Nm
E66051
Installation
2008.50 Kuga 8/2011
G1079153en

TO MODEL INDEX
310-00-1
Fuel System - General Information
310-00-1
SECTION 310-00 Fuel System - General Information

CONTENTS
PAGE

Fuel System Vehicles With: Fuel Additive Tank.............................................................
310-00-2
310-00-2
310-00-2
GENERAL PROCEDURES
Spring Lock Couplings........................................................................................................
310-00-3
Disconnect.......................................................................................................................... 310-00-3
Connect.............................................................................................................................. 310-00-5
Quick Release Coupling.....................................................................................................
310-00-6
Disconnect.......................................................................................................................... 310-00-6
Connect.............................................................................................................................. 310-00-7
Fuel System Pressure Check 2.5L Duratec (162kW/220PS) - VI5................................
310-00-8
Fuel System Pressure Release..........................................................................................
310-00-10
Release.............................................................................................................................. 310-00-10
Fuel Tank Draining..............................................................................................................
310-00-11

TO MODEL INDEX
310-00-2
310-00-2
Fuel System Vehicles With: Fuel Additive Tank

General Equipment
WARNINGS:
This procedure involves fuel additive
handling. Be prepared for fuel additive
spillage at all times and always observe
fuel handling precautions. Failure to follow
injury.
Eye, hand, ear protection and protective
clothing are required to be worn during
any general service or removal and
installation service procedure of fuel
additive system components. Failure to
follow this instruction may result in
personal injury.
In case of fuel additive fluid contact with
the skin or the eyes, flush immediately with
water for a minimum of 15 minutes and
seek prompt medical attention. Failure to
follow these instructions may result in
personal injury.
If fuel additive fluid is swallowed, call a
physician immediately. Rinse mouth
immediately with water, do not induce
vomiting. Failure to follow these
Always provide adequate ventilation when
working on the fuel additive fluid system
or related components. Failure to follow
injury.
Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapors are always
present and may ignite. Failure to follow
injury.
The fuel additive system is an on-board system

that allows the injection of an additive at each
refueling operation by the customer. The additive
quantity is proportional to the fuel quantity that has
been added. The fuel additive system module
controls the amount of additive fluid entering the
fuel tank at each refueling, A switch mounted on
the fuel filler flap is used to detect the start of the
refueling event and the fuel gauge that is mounted
within the fuel tank informs the fuel additive tank
module the quantity of actual fuel added.

2. Visually inspect for obvious signs of leakage
and mechanical or electrical damage.
Mechanical
Fuel additive tank
Fuel additive tank
line(s)
Fuel additive tank
pipe(s)
Fuel additive tank
connector(s)
Fuel tank filler cap
Electrical
Fuse(s)
Fuel filler switch and
magnet
Wiring harness(s)
Electrical
connector(s)
Fuel additive system
module
Fuel additive tank
module
Instrument cluster
Powertrain Control
Module (PCM)
Fuel level sensor

4. If the cause is not visually evident, REFER to
CAUTION: Make sure the workshop area

in which the vehicle is being worked on is
as clean and as dust free as possible.
Foreign matter from working on clutches,
brakes or from machining or welding
operations can contaminate the fuel
system and may result in later malfunction.
2008.50 Kuga 8/2011
G1080718en

TO MODEL INDEX
310-00-3
310-00-3
GENERAL PROCEDURES
Spring Lock Couplings

Special Tool(s)
Materials
310-040
Disconnect Tool, Fuel Line
(5/16")
Name
Engine Oil - 5W-30
Specification
WSS-M2C153-G
Disconnect
23041
WARNINGS:
310-137
Disconnect Tool, Fuel Line
E51255
310-D004
Coupling (3/8" yellow)

(100-00 General Information, Description
and Operation).
NOTE: Fuel supply line connectors are color coded

white. Fuel return line connectors are color coded
red.
1. Release the fuel system pressure
Refer to: Fuel System Pressure Release
23039

310-D005
Coupling (1/2" green)
23-040
412-038
Coupling (5/8" black)
34003
412-069
Coupling (3/4" white)
34002
E77752
2008.50 Kuga 8/2011
G544275en

TO MODEL INDEX
310-00-4
310-00-4
GENERAL PROCEDURES
6.
310-040
VUE0028631
DTV2304094
7. Special Tool(s): 310-D004, 310-D005, 412-038,

412-069
310-040
VUE0028632
GV0906A
5.
8. Special Tool(s): 310-D004, 310-D005, 412-038,
412-069
VUE0028633
GV0907A
2008.50 Kuga 8/2011
G544275en

TO MODEL INDEX
310-00-5
310-00-5
GENERAL PROCEDURES
9.
GV0908A
10. Special Tool(s): 310-D004, 310-D005, 412-038,

412-069
GV0909A
Connect
1.
CAUTION: Only use the specified

material to lubricate the seals.
To connect, reverse the disconnect procedure.
Material: Engine Oil - 5W-30 (WSS-M2C153-G)
engine oil
2008.50 Kuga 8/2011
G544275en

TO MODEL INDEX
310-00-6
310-00-6
GENERAL PROCEDURES
Quick Release Coupling

4.
General Equipment
Disconnect
WARNINGS:
(100-00 General Information, Description
and Operation).
1
E71973
NOTE: Fuel supply line connectors are color coded

white. Fuel return line connectors are color coded
red.
5.
1. Release the fuel system pressure

Refer to: Fuel System Pressure Release
2
1
2.
E53517
6.
2
1
2
E71970
3.
1
2
E38209
3
E71971
2008.50 Kuga 8/2011
G544276en

TO MODEL INDEX
310-00-7
310-00-7
GENERAL PROCEDURES
1
3
E69344
Connect
1. To connect, reverse the disconnect procedure.
2008.50 Kuga 8/2011
G544276en

TO MODEL INDEX
310-00-8
310-00-8
GENERAL PROCEDURES
Fuel System Pressure Check 2.5L Duratec (162kW/220PS) VI5

General Equipment
Adapter Pressure Vacuum Transducer (C219)
Pressure Vacuum Transducer (C407)
4. Connect the following items:

General Equipment: Adapter Pressure
Vacuum Transducer (C219)
General Equipment: Pressure Vacuum
Transducer (C407)

Operation).
C 407

3. General Equipment: Adapter Pressure
C 219
E107164
5. Using the digital multi-meter function, measure

the fuel system pressure.
6. General Equipment: Ford Diagnostic Equipment
650 - 750
3.2
3.6 - 3.4
4 bar
bar
E118167
C 219
7. General Equipment: Ford Diagnostic Equipment
E118166
2 bar
E107203
2008.50 Kuga 8/2011
G544278en

TO MODEL INDEX
310-00-9
310-00-9
GENERAL PROCEDURES
9. Disconnect the following items:
General Equipment: Adapter Pressure
General Equipment: Pressure Vacuum
Transducer (C407)
C 407
C 219
E107164
10. General Equipment: Adapter Pressure

C 219
E118168
2008.50 Kuga 8/2011
G544278en

TO MODEL INDEX
310-00-10
310-00-10
GENERAL PROCEDURES
Fuel System Pressure Release

Release
Operation).
2. Remove the fuel pump and sender unit fuse.
3. Start the engine and allow it to idle until the
engine stalls.
4. Crank the engine for approximately five seconds
to make sure that the fuel rail pressure is
released.
5. Install the fuel pump and sender unit fuse.
2008.50 Kuga 8/2011
G551380en

TO MODEL INDEX
310-00-11
310-00-11
GENERAL PROCEDURES
Fuel Tank Draining

General Equipment
Fluid Container
NOTE: Make sure that a new component is

installed.
Fuel Tank Draining Equipment

Remover/Installer
1. Make sure, that the fuel filler pipe is above
the fuel level .
2. Drain the reservoir.
Activation
General Equipment: Fuel Tank Draining

Equipment
CAUTION: If the fuel tank has been filled

with the wrong type of fuel, the engine
must not be started.
Operation).
8. WARNINGS:
Fuel may still be present in the fuel tank
after draining.
Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
E116177
9. Refer to: Fuel Pump and Sender Unit - 2.5L

Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
10.

escaping fluids.
any escaping fluid.
2008.50 Kuga 8/2011
G1165328en

TO MODEL INDEX
310-00-12
310-00-12
GENERAL PROCEDURES
Drain the reservoir.
E114482

Equipment
E114435
2008.50 Kuga 8/2011
G1165328en

TO MODEL INDEX
310-01-1
Fuel Tank and Lines
310-01-1
SECTION 310-01 Fuel Tank and Lines

CONTENTS
PAGE

Fuel Tank and Lines 2.5L Duratec (147kW/200PS) - VI5 (Component Location).........
Fuel Tank and Lines 2.5L Duratec (147kW/200PS) - VI5 (Overview)............................
Fuel tank.............................................................................................................................
Fuel pump and sender unit.................................................................................................
Fuel filler pipe and tank cap................................................................................................
310-01-2
310-01-5
310-01-5
310-01-5
310-01-6

Fuel Tank 2.5L Duratec (147kW/200PS) - VI5...............................................................
Fuel Level Sensor 2.5L Duratec (147kW/200PS) - VI5.................................................
Fuel Tank Filler Pipe...........................................................................................................
Fuel Filler Nozzle Inhibitor..................................................................................................
Fuel Pump and Sender Unit 2.5L Duratec (147kW/200PS) - VI5..................................
310-01-8
310-01-11
310-01-12
310-01-14
310-01-18

TO MODEL INDEX
Fuel Tank and Lines
310-01-2
310-01-2
Fuel Tank and Lines 2.5L Duratec (147kW/200PS) - VI5

Component Location
1
2
11
10
8
E105870
Item
Description
Item
Description
Fuel pump and level indicator module,

right-hand side
Fuel-filler pipe
EVAP container and lines
EVAP (evaporative emission) extraction

points
Vent hose, fuel filler pipe
Fuel pump and lines for the fuel-fired

booster heater/additional heater

left-hand side
Fuel tank
2008.50 Kuga 8/2011
G1079157en

TO MODEL INDEX
Fuel Tank and Lines
310-01-3
310-01-3

Item
9
Description
Item
Fuel tank retaining straps
Description
10
Line, fuel tank to fuel distribution pipe
11
Connection, fuel-fired booster

heater/additional heater
E105871
Item
Description
Item
Description
Fuel-filler pipe
Overflow hose, fuel filler pipe
Fuel filler opening, capless
EVAP venting/breather hose
Vent hose, fuel filler pipe
Fuel pump and lines for the fuel-fired

booster heater/additional heater
2008.50 Kuga 8/2011
G1079157en

TO MODEL INDEX
Fuel Tank and Lines
310-01-4
310-01-4
7
9
10
11
E105872
Item
Description
Suction hose, left-hand half of the fuel tank
Seal, fuel pump and level indicator

module, left-hand side

right-hand side
Retaining ring, fuel pump and level

indicator module, left-hand side
Nut, fuel pump and level indicator module,

right-hand side
Nut, fuel pump and level indicator module,

left-hand side
Retaining ring, fuel pump and level

indicator module, right-hand side
10
Float, fuel pump and level indicator

module, left-hand side
Seal, fuel pump and level indicator

module, right-hand side
11
Float, fuel pump and level indicator

module, right-hand side
Item
1
2
3
4
5
Description
left-hand side
2008.50 Kuga 8/2011
G1079157en

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Fuel Tank and Lines
310-01-5
310-01-5
Fuel Tank and Lines 2.5L Duratec (147kW/200PS) - VI5

Overview
Fuel tank
The fuel tank is the same on vehicles with FWD
and AWD. The fuel tank is saddle-shaped to
accommodate the drive shaft and the exhaust

system. Depending on the design, the volume of
the tank is 56 liters or 66 liters.
Fuel pump and sender unit
E106247
Item
Description

left-hand side
Comments:
Inactive side without separate fuel pump

right-hand side
2008.50 Kuga 8/2011
G1090887en

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Fuel Tank and Lines
310-01-6
310-01-6

left-hand fuel pump and level indicator module and
pull it out slightly so that the connecting hose can
be detached and the connector for the left-hand
fuel pump and level indicator module can be
disconnected. The left-hand fuel pump and level
indicator module can be removed without detaching
the right-hand fuel pump and level indicator
module.
Changing the right-hand fuel pump and level

indicator module
The instrument cluster uses the signals from both

fuel fill level sensors to determine the fuel fill level.
The resistor tracks of the fuel fill level sensors
cannot be replaced individually.
The fuel filter is designed to last for the service life
of the vehicle and does not need to be replaced.
E113328
If the right-hand fuel pump and level indicator

module needs to be changed on a vehicle with a
booster heater/additional heater, the bore for the
connection to the fuel-fired booster
heater/additional heater must be drilled.
The right-hand fuel pump and level indicator
module contains a demand-switched electric fuel
pump which drives two suction jet pumps. One of
them ensures that fuel is pumped from the left-hand
half of the tank into the right-hand half. On-demand
switching is performed by the fuel pump module.
To remove the right-hand fuel pump and level
indicator module it is necessary to detach the
The right-hand fuel pump and level indicator

module contains an overpressure limiting valve.
This overpressure limiting valve ensures that the
fuel pressure between the injectors and the
right-hand fuel pump and level indicator module
does not exceed 3.3 bar after the engine is
stopped. This reduces the formation of vapor
bubbles and also prevents dripping from the
injectors.
Fuel filler pipe and tank cap

NOTE: Any water in the filling area can cause the
mechanism to freeze at temperatures below 0 C.
In this case the closing mechanism will not open
when the nozzle of the petrol/diesel pump is
inserted.
1
1
5
2
E100648
2008.50 Kuga 8/2011
G1090887en

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Fuel Tank and Lines
310-01-7
310-01-7

Item
Description
Item
Description
Latch mechanism
Gasket
Housing, capless fuel filler pipe
Filler nozzle
Overflow
A spring-loaded fuel filler door closes off the upper

end of the fuel tank filler pipe in place of the filler
cap. The spring-loaded fuel filler door features a
latching mechanism. The release mechanism is
matched to the size of the filler nozzle. If the correct
filler nozzle is inserted, the release lugs are pushed
back. This releases the slide which can move
upwards and opens the way to the spring-loaded
fuel filler door for the filler nozzle.
2008.50 Kuga 8/2011
G1090887en

TO MODEL INDEX
Fuel Tank and Lines
310-01-8
310-01-8
Fuel Tank 2.5L Duratec (147kW/200PS) - VI5

Removal
WARNING: Avoid flames, sparks or lighted
substances.
5. Torque: 15 Nm

4x4
x2
All vehicles
3. Torque: 48 Nm
E113922
x2
6. Torque: 15 Nm
E104225
4.
x4
E113923
E104226
2008.50 Kuga 8/2011
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Fuel Tank and Lines
310-01-9
310-01-9

7. Torque: 15 Nm

any escaping fluid.
Procedures).
x4
E104227
x2
8. Refer to: Fuel Tank Draining (310-00 Fuel
Procedures).
E113944
Vehicles with fuel fired booster heater
All vehicles
9.
12.

escaping fluids.
any escaping fluid.
Procedures).
E113924
10.
E113945
13. Torque: 30 Nm
E113925
11.

escaping fluids.
x4
E104228
2008.50 Kuga 8/2011
G1175018en

TO MODEL INDEX
310-01-10
Fuel Tank and Lines
310-01-10

14.
NOTE: This step is only necessary when installing

a new component.
17.

escaping fluids.
any escaping fluid.
Procedures).
x2
E104859
15.

escaping fluids.
any escaping fluid.
x2
E113927
All vehicles
a new component.
E113946

16.
Installation
x2
E104642
2008.50 Kuga 8/2011
G1175018en

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310-01-11
Fuel Tank and Lines
310-01-11
Fuel Level Sensor 2.5L Duratec (147kW/200PS) - VI5

Removal
Installation
2008.50 Kuga 8/2011
G1000788en

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310-01-12
Fuel Tank and Lines
310-01-12
Fuel Tank Filler Pipe

General Equipment
Fluid Container
General Equipment
Fuel Tank Draining Equipment
Removal
WARNING: Make sure that the fuel tank is
no more than 3/4 full.
3. Torque: 10 Nm

x2
1. Remove the rear wheel on right-hand side.

2.

escaping fluid.
any escaping fluid.
Remover/Installer
E117532
E117531
2008.50 Kuga 8/2011
G1000790en

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Fuel Tank and Lines
310-01-13
310-01-13

4.
WARNING: Fuel may still be present in

the fuel tank after draining.
1. Make sure, that the fuel filler pipe is above
the fuel level.
Remover/Installer
Equipment
1

installed.
NOTE: Make sure that a new clamp is
installed.
NOTE: Make sure that the clamp is installed
to the same orientation as when removed.
Remover/Installer
2. NOTE: Make sure that a new clamp is
installed.
NOTE: Make sure that the clamp is installed
to the same orientation as when removed.
Remover/Installer
E126409
Installation
2008.50 Kuga 8/2011
E117533
G1000790en

TO MODEL INDEX
310-01-14
Fuel Tank and Lines
310-01-14
Fuel Filler Nozzle Inhibitor

Removal
WARNING: Avoid flames, sparks or lighted

substances.

Operation).
2.
E135960
3.
2008.50 Kuga 8/2011
G1375941en

TO MODEL INDEX
310-01-15
Fuel Tank and Lines
310-01-15
E135961
4. Install the special tool(s) (supplied in the parts

kit).
2008.50 Kuga 8/2011
G1375941en

TO MODEL INDEX
310-01-16
Fuel Tank and Lines
310-01-16
E135962
5. 1. Turn until resistance is felt.

1
E135963
2008.50 Kuga 8/2011
G1375941en

TO MODEL INDEX
310-01-17
Fuel Tank and Lines
310-01-17

Installation
1
installed.
2. Turn until resistance is felt.
E135964
2008.50 Kuga 8/2011
G1375941en

TO MODEL INDEX
Fuel Tank and Lines
310-01-18
310-01-18
Fuel Pump and Sender Unit 2.5L Duratec (147kW/200PS) VI5

310-210
Wrench, Fuel Tank Sender
Unit

310-211
Wrench, Fuel Tank Sender
Unit
E115758
E115757
Fluid Container
Removal
4.
1. Refer to: Fuel Tank - 2.5L Duratec

(147kW/200PS) - VI5 (310-01 Fuel Tank and
Lines, Removal and Installation).
Torque: 110 Nm
310-211
E112922
Vehicles without fuel fired booster heater

x2

Procedures).
E114253
3.

damage the fuel tank level sensor float
and arm.
E116270
E112921
2008.50 Kuga 8/2011
G1000791en

TO MODEL INDEX
Fuel Tank and Lines
310-01-19
310-01-19

All vehicles

Torque: 110 Nm
9.
310-210

damage the fuel tank level sensor float
and arm.
x2
E116489

Procedures).
E112979
10.

escaping fluid.
any escaping fluid.
Drain ther reservoir.
E112978
8.
CAUTION: Take extra care when

handling the component terminals.
Torque: 110 Nm
E114482
310-210

a new component.
x2
E116490
2008.50 Kuga 8/2011
G1000791en

TO MODEL INDEX
310-01-20
Fuel Tank and Lines
310-01-20

11.
CAUTION: If either component is

damaged, new paired components must
be installed.
3.
E112980
E116518
Installation

a new component.
2. NOTE: Make sure that the component is clean
and free of foreign material.
Tighten the bolt until the head is sheared off.
E115615

a new component.
2008.50 Kuga 8/2011
G1000791en

TO MODEL INDEX
310-02-1
Acceleration Control
310-02-1
SECTION 310-02 Acceleration Control

CONTENTS
PAGE

Acceleration Control...........................................................................................................
310-02-2
310-02-2

Accelerator Pedal...............................................................................................................
310-02-3

TO MODEL INDEX
310-02-2
310-02-2
Mechanical
Accelerator pedal
Throttle body
Electrical
Wiring harness(s)
Wiring harness
retaining clips
Electrical
connector(s)
Accelerator pedal
Powertrain control
module (PCM)
Electronic throttle
body

2008.50 Kuga 8/2011
G1080719en

TO MODEL INDEX
310-02-3
310-02-3
Accelerator Pedal
Removal
1. Torque: 10 Nm
E79479
Installation
2008.50 Kuga 8/2011
G1065469en

TO MODEL INDEX
310-03-1
Speed Control
310-03-1
SECTION 310-03 Speed Control

CONTENTS
PAGE

Speed Control (Overview)..................................................................................................
Speed Control.....................................................................................................................
Speed Control (System Operation and Component Description).......................................
System Diagram.................................................................................................................
Speed Control.................................................................................................................
Speed control switches...................................................................................................
310-03-2
310-03-2
310-03-3
310-03-3
310-03-4
310-03-4
310-03-6
310-03-6

Speed Control.....................................................................................................................
310-03-7
310-03-7

TO MODEL INDEX
310-03-2
Speed Control
310-03-2
Speed Control Overview

Speed Control
The cruise control system keeps the vehicle to a
target speed selected by the driver. The cruise
control system is controlled by the PCM (powertrain
control module)
WARNING: The cruise control system may
not be used in heavy traffic, on winding
roads or on a slippery road surface.
To remove the buttons for the cruise control
system, the airbag must be removed. The buttons
for the two control switch units cannot be replaced
individually.
2008.50 Kuga 8/2011
G1015505en

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Speed Control
310-03-3
310-03-3
Speed Control System Operation and Component Description

System Diagram
1
13
12
11
10
E96584
Item
Description
Item
Control switch units - Cruise control

Refer to Component Description: Speed
control switches (page 6)
Instrument cluster
VSS (vehicle speed sensor)
ABS (anti-lock brake system) module

Comments:
Vehicles with automatic transaxle.
Steering wheel module

Comments:
Contains the coil spring
2008.50 Kuga 8/2011
Description
G1044191en

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Speed Control
310-03-4
310-03-4

Item
Description
Item
Description
PCM
11
Throttle body
Comments:
Contains the TP (throttle position) sensor
CPP (clutch pedal position) switch

Comments:
12
BPP (brake pedal position) switch
13
Reverse gear solenoid

Comments:
10
The APP (accelerator pedal position)

sensor.
System Operation
Speed Control
Cruise control is integrated into PCM and
intervenes in engine management to automatically
keep to the target speed selected by the driver.
When the system is active, the vehicle can be
accelerated or decelerated without the accelerator
pedal being pressed. Cruise control is operated
using the control switch units on the steering wheel.
Cruise control can only be changed into "ACTIVE"

mode under the following conditions:
2nd - 6th gear engaged.
Engine speed between idle speed and maximum
permissible speed.
Vehicle speed at least 40 km/h.
The PCM controls the throttle to achieve this. The

ABS module supplies the VSS signal for this.
Pressing the "SET+" or "SET-" button activates

cruise control ("ACTIVE" mode). The green "Cruise
control" indicator lamp in the instrument cluster
lights up. The current vehicle speed is saved as
the target.
On vehicles with automatic transmission, the TCM

receives a notification via the CAN (controller area
network) bus that cruise control is active. The TCM
then controls the transmission based on special
engine maps.
Cruise control recognizes three operating modes:
"OFF": Control is switched off.
"STANDBY": Control is switched on but not
active. The speed of the vehicle is not regulated
by the cruise control.
"ACTIVE": Control is switched on and active.
Cruise control adjusts the vehicle speed to the
stored or desired target speed.
Every time the engine is started, cruise control is
in the "OFF" mode. In this mode, only the "ON"
button is operable.
Cruise control is initially set to "STANDBY" mode
when the "ON" button is pressed. The green cruise
control indicator lamp in the instrument cluster
lights up. There is no target speed saved.
Cruise control can only be set to "STANDBY" mode
Engine speed is between idle speed and
maximum permissible speed.
2008.50 Kuga 8/2011
In "ACTIVE" mode the "OFF", "SET+", "SET-" and

"RES" buttons are active. If the "RES" button is
pressed again, control is suspended. The "RES"
button has a dual function and is used to resume
and suspend the cruise control.
Tapping the "SET+" button (for less than 640 ms)
increases the target speed by 1 km/h at a time.
Holding down the "SET+" button (for longer than
640 ms) increases the target speed until the button
is released. If the button is not released, cruise
control accelerates the vehicle up to the maximum
permissible vehicle speed (200 km/h) or up to the
vehicle's maximum speed (whichever speed is
lower). Tapping the "SET-" button (for less than
640 ms) reduces the target speed by 1 km/h at a
time. When the the "SET-" button is held down, the
control reduces the target speed until the button is
released. If the "SET-" button is held down until
the minimum speed of 40 km/h is reached, cruise
control switches to "STANDBY" mode.
Cruise control is put into "STANDBY" mode when
the "RES" button is pressed. Control to the stored
target speed can be started again by pressing the
"RES" button again. If the "SET+" or "SET-" button
is pressed while the "RES" function is being
performed (control to saved target speed), cruise
G1044191en

TO MODEL INDEX
310-03-5
Speed Control
310-03-5

control saves the current speed as the target
speed.
Cruise control goes into STANDBY mode in the
following situations:
Operation of the brake pedal
Operation of the clutch pedal
Operation of the parking brake
If the driver operates the accelerator pedal and
the saved target speed is subsequently
exceeded for more than 5 minutes.
Pressing any cruise control button for more than
2 minutes
Intervention by the traction control or electronic
stability program (for longer than 40 ms)
Shifting of the gear selector lever to the "N"
position (vehicles with automatic transmission
only)
Minimum speed falls below 40 km/h.
Occurrence of particular DTC (diagnostic trouble
code)
faulty signal from the backup lamp switch
Cruise control is switched off when the "OFF"
button is pressed.
If the accelerator pedal is pressed down, the
vehicle speed increases. As soon as the pedal is
released, the speed falls to the saved target value.
2008.50 Kuga 8/2011
The following components supply the signals

needed by the cruise control:
The APP sensor.
The APP sensor identifies the current
position of the accelerator pedal and sends
a PWM (pulse width modulation) signal to
the PCM and an analog DC (direct current)
signal to the GEM.
If one or both of the APP sensors fails, a fault
is stored in the PCM fault memory and cruise
control cannot be activated.
BPP switch
The BPP switch tells the PCM whether the
vehicle is being braked. In its rest state the
switch is closed and sends an earth signal
to the GEM. This signal is sent via the CAN
to the PCM.
The brake light switch is likewise connected
to the GEM and is opened in the rest state.
When the vehicle is braked, the brake light
switch sends a signal to the GEM. This
compares the signals from the BPP switch
and the brake light switch. If a discrepancy
occurs, a fault is stored in the error memory
of the GEM. Cruise control cannot be
activated.
CPP switch
The CPP switch sends a ground signal to the
GEM as soon as the clutch is operated. This
signal is passed on by the GEM via the CAN
bus to the PCM. This then supplies the signal
to the cruise control.
If the CPP switch is incorrectly installed or
set, cruise control cannot be activated.
Wheel speed sensors
The wheel speed sensors record the speed
of all the wheels. The recorded speed values
are sent to the ABS module via a hard-wired
connection. The ABS module calculates a
vehicle speed signal (VS signal) from the
speed values and the wheel diameter. This
vehicle speed signal is transferred via the
CAN bus to the PCM and supplied to the
cruise control. If the vehicle speed signal is
faulty, cruise control cannot be activated.
G1044191en

TO MODEL INDEX
Speed Control
310-03-6
310-03-6

Parking brake switch.
The parking brake switch is hard-wired to the
GEM. The parking brake switch sends a
signal to the GEM when the parking brake is
operated. The GEM activates the parking
brake indicator lamp in the instrument cluster.
If the parking brake indicator lamp is lit,
cruise control cannot be activated.
Back-up light switch
The backup lamp switch is hard-wired to the
GEM. The backup lamp switch sends a signal

to the GEM when reverse gear is engaged.
The GEM activates the reversing lamp.
Cruise control cannot be activated when
reverse gear is engaged.
Speed control switches
1
4
2
5
E103768
Item
1
2
Description
Item
Description
"ON" button
Comments:
"RES" button
"SET+" button
"OFF" button
"SET-" button
The cruise control buttons are non-locking push

buttons. They are connected to the coil spring via
a hard-wired 9-pin plug connection.
The cruise control buttons operate according to
the resistance bridge circuit principle. The buttons
receive a 5 Volt reference voltage. When operated,
each button passes a particular voltage to the
GEM. The GEM measures this voltage and from
it determines which button has been pressed.
The operation of the cruise control buttons can be
checked by a simple measurement of the
resistance between pin 4 and pin 5 at the coil
spring 9-pin connector. A change of resistance
must occur when a button is pressed.
2008.50 Kuga 8/2011
G1044191en

TO MODEL INDEX
Speed Control
310-03-7
310-03-7
Speed Control
system.
Mechanical
Brake pedal
Clutch pedal
Electrical
Fuse(s)
Connections
Wiring harness
Clockspring
Loose or corroded
electrical
connector(s)
Speed control
switch
Brake pedal position
(BPP) deactivation
switch
Clutch pedal position (CPP) deactivation Switch
Powertrain control
module (PCM)
Central junction box
(CJB)
3. NOTE: Not all passenger junction box (PJB)

variants support the speed control system.
NOTE: If the PJB is configured for speed control
disable, speed control operation is not transmitted,
no Diagnostic Trouble Codes (DTCs) are
generated.
If an obvious cause for an observed or reported
2008.50 Kuga 8/2011
G1054908en
BACK TO MAIN INDEX

TO MODEL INDEX
*5283
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.XJD

TO MODEL INDEX
412-00-1
Climate Control System - General Information
412-00-1
SECTION 412-00 Climate Control System - General

Information
CONTENTS
PAGE
SPECIFICATIONS
Specifications......................................................................................................................
412-00-2

Climate Control System......................................................................................................
Refrigerant Circuit - Quick Check.......................................................................................
Sequence of A/C Request Signal.......................................................................................
412-00-3
412-00-3
412-00-3
412-00-4
GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing.............................................................................
Air Conditioning (A/C) System Recovery, Evacuation and Charging.................................
Spring Lock Coupling..........................................................................................................
Air Conditioning (A/C) Clutch Air Gap Adjustment.............................................................
Refrigerant Oil Adding........................................................................................................
Contaminated Refrigerant Handling...................................................................................
Electronic Leak Detection...................................................................................................
Fluorescent Dye Leak Detection........................................................................................
Vacuum Leak Detection......................................................................................................
412-00-6
412-00-7
412-00-9
412-00-11
412-00-12
412-00-13
412-00-14
412-00-15
412-00-16

TO MODEL INDEX
412-00-2
412-00-2
SPECIFICATIONS
Specificat
ions
Refrigerant R134a
Specificat
ions
Refrigerant oil
WSH-M17
B19-A
WSH-M1C
231-B
Refrigerant Capacities (When Charging)

grams
Air Conditioning
600 15
Refrigerant Oil Capacities (When Charging)

millilitres
Air Conditioning
200
Addition of Refrigerant Oil (When new components are installed)

CAUTIONS:
The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.
If other A/C components are being renewed in addition to the A/C compressor, there is no
need to top up with additional refrigerant oil, apart from filling the compressor.
Because the fill quantities differ, the refrigerant oil must be drained from the new A/C
compressor.
millilitres
After renewal of all lines and components.
add 200.
Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained

from the faulty compressor is less than 150 ml
add 150.
Air conditioning compressor (if the amount of refrigerant oil drained from the
faulty compressor is more than 150 ml)
add 200.
A/C condenser
add 30.
A/C evaporator
add 30.
A/C dehydrator
add 90.
Always, if refrigerant was drained.
Add the same quantity

as the quantity that was
collected.
Clutch air gap

mm
Compressor clutch air gap
Item
Compressor drive plate retaining bolt
2008.50 Kuga 8/2011
0,35 - 0,75
Nm
lb-ft
lb-in
13
10
G1065477en

TO MODEL INDEX
412-00-3
412-00-3
Climate Control System

Terminal Probe Kit
418-S035
29011A
Digital Multimeter (compatible with K-type

thermocouple)
the Ford approved diagnostic tool and RECTIFY

the fault(s) displayed in accordance with the
fault description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s), PROCEED
in accordance with the Symptom Chart
according to the fault symptom.
6. Following checking or elimination of the fault(s)
and after completion of operations, the fault
memories of all vehicle modules must be READ
OUT and any stored faults must be DELETED.
Refrigerant Circuit - Quick Check

Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)

NOTE: The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or
electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection
Mechanical
Refrigerant lines
Condenser core
Coolant level
Drive belt
A/C compressor
Electrical
Fuses
Wiring harness
Connector
3. RECTIFY any obvious causes for a concern

found during the visual inspection before
performing any further tests. CHECK the
operation of the system.
4. If the concern is still present after the visual
inspection, perform fault diagnosis on the
electronic engine management, the charging
system, the generic electronic module (GEM)
and the instrument cluster (vehicles with EATC:
read out the EATC fault memory as well) using
2008.50 Kuga 8/2011
WARNING: The air conditioning system is

filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Refrigerant circuit check
WARNING: Under certain circumstances,

refrigerant lines and A/C components may
be extremely hot or cold. Exercising care,
touch the refrigerant lines or A/C
components in order to check this. Failure
to follow these instructions may result in
personal injury.
When the A/C system is operating, the following
conditions should apply:
The refrigerant line from the refrigerant
compressor to the condenser must be hot.
The refrigerant line from the A/C condenser to
the fixed orifice tube must be warm, but not so
hot as the refrigerant line mentioned above.
Determine the difference in temperature
upstream and downstream of the A/C condenser
by measuring the temperatures at the refrigerant
lines. The temperature difference should be
more than 20 C, depending on the ambient
temperature. If the temperature difference is
less, check the condenser for contamination or
damage to the fins as well as operation of the
radiator fans.
G1055878en

TO MODEL INDEX
412-00-4
412-00-4

The refrigerant line between the fixed orifice
tube and the evaporator must be cold from the
point where the fixed orifice tube is installed.
Depending on the weather, the refrigerant line
may also have ice on its surface.
The refrigerant line between the evaporator and
the A/C compressor including the dehydrator
must be cold.
Evaporator outlet line temperature test
To test the power of the A/C system, the

temperature at the evaporator outlet line must be
measured. To do this, the following preconditions
must be met:
Open all windows.
Set the air distribution to the defrost/dashboard
position and open all the ventilation nozzles.
DO NOT switch on recirculated air.
Select lowest blower switch setting.
Select lowest temperature setting.
NOTE: The temperature measurement cannot be
done with a thermometer which makes no contact.
The surface reflection from the metal line may
cause incorrect readings.
Connect the temperature sensor (Fluke 80 PK-8)
to the outlet line of the evaporator. Locate the
temperature sensor as close as possible to the
evaporator. Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed
for several minutes.
No or poor cooling performance:

Blockage or narrowing of a refrigerant line or
in the dehydrator. The location of the
blockage or narrowing can easily be located
by temperature comparisons at the
refrigerant lines and the dehydrator. The
blockage or restriction is located at the point
where the temperature difference is
identified. Note: A temperature difference
in the area of the fixed orifice tube is
normal. If the location of the blockage or
narrowing is found, check the corresponding
component and renew as applicable.
Sudden drop in cooling performance (after the
air conditioning has been switched off for
approx. 5 minutes, the cooling performance
returns to normal):
The cause is an iced-up fixed orifice tube
because of moisture in the refrigerant circuit.
In order to ensure that moisture is completely
removed from the refrigerant circuit, the
dehydrator should be renewed and the
evacuation time should be extended to 2-3
hours. For further information
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Sequence of A/C Request Signal
Switch on the A/C.
NOTE: The electronic automatic temperature

control (EATC) module is integrated into the air
conditioning control assembly.
After three minutes, measure the surface

temperature of the evaporator outlet line.
NOTE: The generic electronic module (GEM) is

an integral part of the central junction box (CJB).
If the temperature measured is 4 C or lower, the

A/C system is OK. If the temperature is higher, the
A/C system may be under-filled. For further
information, refer to
After actuating the A/C ON/OFF switch integrated

into the A/C control assembly, an A/C request
signal is sent from the A/C control assembly
(vehicles with EATC: EATC module) to the GEM.

From there, the signal is sent to the instrument

cluster via the MS-CAN bus. A gateway is installed
in the instrument cluster, which establishes the
connection between the MS-CAN bus and the
HS-CAN bus.
Frequent faults and their causes
If the cooling power of the A/C system is not

adequate, make certain that the temperature
control flap(s) is/are operating correctly.
2008.50 Kuga 8/2011
After the signal has been converted in the gateway,

it is relayed to the powertrain control module (PCM)
via the HS-CAN bus. Once all the required
parameters have been met, the PCM switches on
the refrigerant compressor and thus the A/C system
via the A/C clutch relay.
G1055878en

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412-00-5
412-00-5

2008.50 Kuga 8/2011
G1055878en

TO MODEL INDEX
412-00-6
412-00-6
GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing

9. Information not available at this time.
2008.50 Kuga 8/2011
G1438314en

TO MODEL INDEX
412-00-7
412-00-7
GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and Charging

General Equipment
Air Conditioning Service Unit
4. 1. Low-pressure connection
2. High-pressure connection
Automatic Calibration Halogen Leak Detector

1
Electronic Leak Detector

Refrigerant Identification Equipment
UV Leak Detector
2.
2
E51608
5. Connect the service unit lines to the filling

connection of the air conditioning system.
x4
E100846
3.
CAUTION: The refrigerant analyzer must

be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous
waste. Always follow the manufacturer's
instructions when using the refrigerant
center and the refrigerant analyzer.
Unscrew and remove the protective caps from
the A/C charging connections.
General Equipment: Air Conditioning Service
Unit
General Equipment: Refrigerant Identification
Equipment
VFE0031288
6. Drain the air conditioning system via the

low-pressure port in accordance with the service
unit manufacturer instructions.
7.
CAUTION: Make sure that the specified

amount of refrigerant oil is added.
NOTE: This step is only required when installing
a new component.
Fill up with refrigerant oil.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
8. Evacuate the air conditioning system in

accordance with the service unit manufacturer
instructions.
9. NOTE: The system is leak-tight if the pressure
increase does not exceed 20 mbar.
2008.50 Kuga 8/2011
G1022208en

TO MODEL INDEX
412-00-8
412-00-8
GENERAL PROCEDURES
Perform the leak test, by closing the hand valves
on the gauge set, switching off the service unit
vacuum pump and observing the low pressure
gauge.
10. NOTE: This step is only necessary if the
pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C
refrigerant circuit using a leak tester.
17. 1. Close the shut-off valve.

2. Switch off the service unit.
3. Disconnect the service unit lines from the
filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging
connections.
18. Install all components in reverse order.
General Equipment: UV Leak Detector

General Equipment: Electronic Leak Detector
General Equipment: Automatic Calibration
Halogen Leak Detector
11. Add refrigerant oil to the air conditioning system.
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
12. Fill the air conditioning system with liquid
through the high-pressure connection.
13. 1. Open the shut-off valve on the high-pressure
side.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
liquid refrigerant (R134a).
14. Fill the air conditioning system with gas through
the low-pressure connection.
15. 1. Open the shut-off valve on the low-pressure
side.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with
the air conditioning switched on. To do so
run the engine at about 1200-1500 rev/min.
Set the air conditioning system to full cooling
power and fresh air mode. Set the blower
motor to the highest setting. Fill with the
remainder of the specified fill capacity.
16. Disconnect the service unit.
2008.50 Kuga 8/2011
G1022208en

TO MODEL INDEX
412-00-9
412-00-9
GENERAL PROCEDURES
Spring Lock Coupling

Special Tool(s)
412-026
Coupling (3/8" red)

2. NOTE: Choose the special tool according to the
line diameter.
Special Tool(s): 412-026, 412-027, 412-038,
412-069
23023A
412-027
Coupling (1/2" blue)
34001
412-038
Coupling (5/8" black)
E68499
3.
34003
412-069
Coupling (3/4" white)
34002
Materials
Name
Conditioning
E68500
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
4.

are sealed.
E68501
2008.50 Kuga 8/2011
G549834en

TO MODEL INDEX
412-00-10
412-00-10
GENERAL PROCEDURES
5.

are sealed.
Check the locking spring for damage.
Carefully remove damaged locking springs
with a thin wire, and renew them.
E68502
6. Install new refrigerant line O-rings.
E68523
7.
CAUTION: Never lubricate connections

and O-rings with mineral oil.
Coat the O-rings for the refrigerant line with
clean refrigerant oil.
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
8.
E68503
2008.50 Kuga 8/2011
G549834en

TO MODEL INDEX
412-00-11
412-00-11
GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment

1. Check the gap A (measure the difference
between the engaged and disengaged positions
of the air conditioning clutch) at 60 intervals
around the circumference of the pulley. Operate
the air conditioning clutch several times with the
aid of a 5 A fused cable. Refer to the relevant
wiring diagram for the correct electrical
connection.
3. If necessary correct the gap A using spacer

washers.

E68470
4. Refer to: Specifications (412-00 Climate Control

E68442
5. Check the gap A as described in step 1. If

necessary, repeat steps 2-5.
E92144
2.
E68442
2008.50 Kuga 8/2011
G549835en

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412-00-12
412-00-12
GENERAL PROCEDURES
Refrigerant Oil Adding

CAUTION: Collect the refrigerant oil in a
clean measuring cylinder.
1. NOTE: This step only needs to be carried out
when removing the A/C compressor.
NOTE: Rotate the compressor shaft at least 6
to 8 turns when draining the refrigerant oil.
Drain the refrigerant oil from the defective A/C
compressor and dispose of it.
2. CAUTIONS:
The refrigerant oil top-up quantity must
not exceed the refrigerant oil fill
quantity.
If other A/C components are being
renewed in addition to the A/C
compressor, there is no need to top up
with additional refrigerant oil, apart from
filling the compressor.
Top up with the calculated quantity of new
refrigerant oil. See: Specifications (412-00
Heating, Ventilation, Air-Conditioning - General
information, Specifications).
2008.50 Kuga 8/2011
G549839en

TO MODEL INDEX
412-00-13
412-00-13
GENERAL PROCEDURES
Contaminated Refrigerant Handling

1.
CAUTION: Any R134a or R12 refrigerant

which is contaminated with unsuitable
refrigerant should be extracted only by
means of a suitable servicing unit
designed for the purpose of collecting
and storing contaminated refrigerant,
so that the spread to other vehicles can
be prevented.
Use refrigerant identification equipment to check
that there is contaminated refrigerant in the air
conditioning system.
2. Inform the customer about the additional costs

involved to repair the system because of the
contamination.
3. Extract the contaminated refrigerant.
2008.50 Kuga 8/2011
G549840en

TO MODEL INDEX
412-00-14
412-00-14
GENERAL PROCEDURES
Electronic Leak Detection

2. WARNINGS:
Before starting leak detection, make
sure that the area where it is to be done
is well ventilated. If the surrounding air
is contaminated with refrigerant gas, the
leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc
brake cleaner, or other cleaning
solvents can cause the same problem.
Prevent air movement while performing
leak detection.
The refrigerant identification equipment
must be used before attaching the
manifold gauge set. Otherwise the
manifold gauge set may become
contaminated. Contaminated refrigerant
must be disposed of as special waste.
Follow the manufacturer's instructions
when working with the service unit.
NOTE: At 24C with the engine switched off,
both manifold gauges should show 4.1 to 5.5
bar.
Attach the manifold gauge set to the service
gauge port valves.
3. For the leak test, close the manual valves on
the gauge set.
4. If little or no pressure is indicated, charge the
system with approx. 300g of refrigerant. Refer
to: Air Conditioning System - Evacuate and
Refill.
5. Use the R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant system.
Follow the instructions included with leak
detector for handling and operation techniques.
6. If any leak is found, extract the refrigerant under
suction. Refer to: Air Conditioning System Evacuate and Refill.
2008.50 Kuga 8/2011
G549836en

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412-00-15
412-00-15
GENERAL PROCEDURES
Fluorescent Dye Leak Detection

General Equipment
UV Leak Detector
2. NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. The
cause of this may be a procedure used in
production before installation of the fittings in
order to assist their assembly. When a spring
lock coupler is suspected of leaking, always
wipe the fitting clean and verify the leak with
R-134a Automatic Calibration Halogen Leak
Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak can
exist, always inspect each component.
Locate the leaks. Check all components,
fittings and lines of the A/C system for leaks.
General Equipment: UV Leak Detector
3. After the leak is found and rectified, remove any
traces of dye with a general purpose solvent.
4. Check the repair by operating the system for
some minutes and inspecting with the UV lamp
again.
2008.50 Kuga 8/2011
G1065493en

TO MODEL INDEX
412-00-16
412-00-16
GENERAL PROCEDURES
Vacuum Leak Detection

1. Carry out the air conditioning (A/C) system
recovery procedure.
Refer to: Air Conditioning (A/C) System
2008.50 Kuga 8/2011
G1065495en

TO MODEL INDEX
412-01-1
Climate Control
412-01-1
SECTION 412-01 Climate Control

CONTENTS
PAGE
PAGE 1 OF 2
SPECIFICATIONS
Specifications......................................................................................................................
412-01-3

Climate Control (Component Location)..............................................................................
Climate Control (Overview)................................................................................................
Pollen filter..........................................................................................................................
Heat exchanger..................................................................................................................
Evaporator assembly..........................................................................................................
Blower motor......................................................................................................................
Fault Memory Interrogation without diagnostics unit - vehicles with automatic temperature
control...............................................................................................................................
Switch over from Celsius to Fahrenheit..............................................................................
Climate Control (System Operation and Component Description).....................................
System Diagram.................................................................................................................
Climate control housing..................................................................................................
Climate control................................................................................................................
Air conditioning compressor...........................................................................................
Pollen filter......................................................................................................................
Control assembly, climate control - vehicles with manual temperature control..............
Control assembly, climate control - vehicles with automatic temperature control...........
Control assembly, climate control - vehicles with DVD navigation system with a touch
screen...........................................................................................................................
Climate control module - vehicles with DVD navigation system with a touch screen.....
Sun sensor - vehicles with automatic temperature control.............................................
In-vehicle temperature sensor........................................................................................
Ambient temperature sensor..........................................................................................
Blower motor...................................................................................................................
Blower control module - vehicles equipped with automatic temperature control............
412-01-4
412-01-10
412-01-10
412-01-10
412-01-10
412-01-10
412-01-11
412-01-11
412-01-12
412-01-12
412-01-19
412-01-19
412-01-22
412-01-24
412-01-24
412-01-24
412-01-24
412-01-25
412-01-25
412-01-25
412-01-25
412-01-26
412-01-26
412-01-26
412-01-26

Air Conditioning (A/C) Compressor 2.5L Duratec (147kW/200PS) - VI5.... (34 626 4)
Air Conditioning (A/C) Compressor to Condenser Discharge Line.....................................
Air Conditioning (A/C) Compressor to Condenser Discharge Line 2.5L Duratec
(147kW/200PS) - VI5........................................................................................................
Condenser..........................................................................................................................
Clutch and Clutch Field Coil...............................................................................................
Pollen Filter RHD...........................................................................................................
Blower Motor RHD..................................................................................... (34 374 0)
Blower Motor Resistor Vehicles With: Manual Temperature Control, RHD. (34 382 0)
Blower Motor Resistor Vehicles With: Dual Automatic Temperature
Control.......................................................................................................... (34 382 0)
412-01-28
412-01-29
412-01-30
412-01-31
412-01-35
412-01-36
412-01-37
412-01-40
412-01-41
412-01-2

TO MODEL INDEX
Climate Control
412-01-2
PAGE 2 OF 2
Heater Core and Evaporator Core Housing.......................................................................

Heater Core RHD....................................................................................... (34 364 0)
Suction Accumulator...........................................................................................................
Suction Accumulator to Air Conditioning (A/C) Compressor Line......................................
Suction Accumulator to Air Conditioning (A/C) Compressor Line 2.5L Duratec
(147kW/200PS) - VI5........................................................................................................
Low-Pressure Cutoff Switch...............................................................................................
High-Pressure Cutoff Switch...............................................................................................
Evaporator..........................................................................................................................
Evaporator Outlet Line........................................................................................................
Evaporator Core Orifice......................................................................................................
Condenser to Evaporator Line............................................................................................
Climate Control Assembly Vehicles With: Manual Temperature Control.... (34 300 0)
Climate Control Assembly Vehicles With: Automatic Temperature Control. (34 300 0)
Footwell Air Discharge Temperature Sensor.................................................. (34 485 4)
Center Register Air Discharge Temperature Sensor..........................................................
In-Vehicle Temperature Sensor..........................................................................................
Ambient Air Temperature Sensor................................................................... (34 676 0)
Sunload Sensor.............................................................................................. (34 665 0)
Footwell Vent/Duct Blend Door Actuator RHD........................................... (34 591 0)
Air Inlet Blend Door Actuator.......................................................................... (34 606 0)
Driver Side Temperature Blend Door Actuator............................................... (34 608 0)
Passenger Side Temperature Blend Door Actuator....................................... (34 608 0)
Defrost Vent/Register Blend Door Actuator RHD...................................... (34 591 0)
412-01-42
412-01-45
412-01-53
412-01-56
412-01-57
412-01-58
412-01-59
412-01-60
412-01-62
412-01-65
412-01-68
412-01-71
412-01-72
412-01-73
412-01-74
412-01-75
412-01-76
412-01-77
412-01-78
412-01-79
412-01-80
412-01-81
412-01-82
412-01-3

TO MODEL INDEX
Climate Control
412-01-3
SPECIFICATIONS
A/C compressor
Description
A/C compressor (vehicles with 2.0L Duratorq-TDCi (DW 10) engines)
Visteon VS16
A/C compressor (vehicles with 2.5L Duratec-ST (VI5) engine)
Zexel KC88
2008.50 Kuga 8/2011
G1158274en

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Climate Control
412-01-4
412-01-4
Climate Control Component Location

Air distribution, instrument cluster
4
6
1
5
2
E97259
Item
Description
Item
Air passages - side window defroster vents
Air passages - center vents
Air passages - side vents (adjustable)
Air ducts, rear footwell
Air passages defroster vents
Air ducts, front footwell
2008.50 Kuga 8/2011
Description
G1034943en

TO MODEL INDEX
Climate Control
412-01-5
412-01-5

Air distribution, passenger compartment
4
4
2
E97260
Item
Description
Item
Description
Air duct, demister vents
Air ducts, front footwell
Control assembly, climate control - vehicles with

manual temperature control
E97585
2008.50 Kuga 8/2011

automatic temperature control
E97586
G1034943en

TO MODEL INDEX
412-01-6
Climate Control
412-01-6

DVD navigation system with a touch screen
E97587
Sun sensor - vehicles with automatic temperature

control
E97590
Climate control module - vehicles with DVD

navigation system with a touch screen
Blower control module - vehicles equipped with

E68600
E78221
2008.50 Kuga 8/2011
G1034943en

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Climate Control
412-01-7
412-01-7

Climate control
E97591
Item
Description
Item
Description
Condenser
Dual pressure switch
Low pressure filling connection
High pressure filling connection
Low pressure limiting switch
Refrigerant drier
Evaporator Core Orifice Tube
Evaporator assembly
2008.50 Kuga 8/2011
G1034943en

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Climate Control
412-01-8
412-01-8

Climate control housing - vehicles with manual temperature control
1
6
2
7
4
9
3
E97588
Item
Description
Item
Description
Air flap actuator
Control unit - air distribution

flap/temperature control flap
Operating lever - air distribution flap central nozzles
Operating lever - temperature control flap
Operating lever - air distribution flap demister vents
Operating lever - air distribution flap footwell
Rod - air distribution flap
Operating cable - temperature control flap
Blower motor resistor
2008.50 Kuga 8/2011
G1034943en

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Climate Control
412-01-9
412-01-9

Climate control housing - vehicles with automatic temperature control
2
9
7
8
3
E97589
Item
Description
Item
Description
Air flap actuator
Actuator - air distribution flap - demister

vents
Air outlet temperature sensors - center

vents
Operating unit - air distribution flaps
Actuator - right-hand temperature control

flap
Actuator - air distribution flap - center

vents
Air outlet temperature sensors - footwell
Actuator - left-hand temperature control

flap
Blower control module
2008.50 Kuga 8/2011
G1034943en

TO MODEL INDEX
412-01-10
Climate Control
412-01-10
Climate Control Overview

Pollen filter
Evaporator assembly
E97258
E97250
The pollen filter must be changed at intervals in

accordance with the service schedule. A special
production pollen filter is installed in the factory,
and this must be cut through when the filter is
changed. The service pollen filter is flexible and
can be pushed together during installation or
removal.
Heat exchanger
The evaporator is located on the right-hand side

of the climate control housing (LHD and RHD). It
can only be removed and installed with the climate
control housing still installed in the vehicle, and the
heat exchanger must be removed at the same time.
Blower motor
CAUTION: Make sure that the blower motor
and fan assembly is placed on the bench
with the fan pointing upwards.
412-131
E97249
The heat exchanger is accessible from the

right-hand side of the climate control housing (LHD
and RHD). It can be removed and installed with
the climate control housing still installed in the
vehicle. During removal, the coolant pipes of the
production heater core must be sawn through.
During servicing, a heater core with separate
coolant pipes is installed.
2008.50 Kuga 8/2011
E101398
To prevent damage to the fan wheel vanes, the

fan wheel must not be touched. For this reason, a
special tool (412-131) has been introduced for
removal and installation of the blower motor. This
tool is pushed onto the central shaft in order to lift
out the blower motor.
G1034945en

TO MODEL INDEX
412-01-11
Climate Control
412-01-11

Fault Memory Interrogation without
diagnostics unit - vehicles with
NOTE: On vehicles equipped with a DVD
navigation system with touchscreen, the fault
memory can only be interrogated using the Ford
diagnostic tool.
Switch over from Celsius to Fahrenheit

The switch from Celsius to Fahrenheit is performed
on the display of the instrument cluster and is then
transmitted via the CAN bus to the module of the
two-zone air conditioning system.
The climate control and heating system features

a on-board diagnosis function which can detect
and store both current permanent faults as well as
intermittent faults which have occurred during
normal operation of the vehicle. It is also possible
to read out these faults via the display on the
control panel of the climate control system. To read
out the fault memory, the ignition key must be
turned to the "ON" position and the battery voltage
must be between 9 V and 16 V.
To activate the on-board diagnosis at the control
panel for the climate control system, PRESS the
"OFF" and "FOOTWELL" buttons simultaneously
for exactly 2 seconds, then PRESS "AUTO" within
1.5 seconds. The on-board diagnosis which then
starts lasts a few seconds. An animated display
appears in the display of the control panel for the
climate control system during this time. Any faults
found are displayed on both displays of the control
panel for the climate control system in the form of
trouble codes.
To read out saved errors at the control panel for
the climate control system, PRESS the "OFF" and
"FOOTWELL" buttons simultaneously for exactly
2 seconds, then PRESS "HEAD AREA" within 1.5
seconds. Any stored faults are shown on the
display of the control panel for the climate control
system and should be noted for safety reasons.
By PRESSING the "DEFROST" button, the fault
memory is cleared and diagnosis mode is ended.
To end the diagnostic mode without clearing the
DTCs, PRESS any other operating button on the
control panel for the climate control system.
To read out the software version at the control
panel for the climate control system, PRESS the
"OFF" and "FOOTWELL" buttons simultaneously
for exactly 2 seconds, then PRESS "A/C" within
1.5 seconds. The software version is shown on the
display of the control panel for the climate control
system. The output mode can be exited by
PRESSING any button on the control panel for the
climate control system.
2008.50 Kuga 8/2011
G1034945en

TO MODEL INDEX
Climate Control
412-01-12
412-01-12
Climate Control System Operation and Component Description

System Diagram
Climate control system - vehicles with manual temperature control
E97574
Item
Description
Item

Refer to Component Description: Control
assembly, climate control - vehicles with
manual temperature control (page 24)
Blower motor resistor
Blower motor
Description
Air flap actuator
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-13
412-01-13

Climate control system - vehicles with automatic temperature control
16
3
15
5
2
14
6
13
1
12
7
11
MS-CAN
8
9
10
E97575
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-14
412-01-14

Item
Description
Item

automatic temperature control (page 25)
10

Ambient temperature sensor (page 26)
11
Air outlet temperature sensor - left-hand

center vents
12
Blower motor
26)
Air outlet temperature sensor - right-hand

center vents
13

footwell
Air flap actuator
14

flap

footwell
15
Solar sensor
Refer to Component Description: Sun
sensor - vehicles with automatic
temperature control (page 25)
16
In-vehicle temperature sensor

26)

Refer to Component Description: Blower
control module - vehicles equipped with

flap

vents

vents
2008.50 Kuga 8/2011
Description
G1034947en

TO MODEL INDEX
Climate Control
412-01-15
412-01-15

Climate control system - vehicles with DVD navigation system with a touch screen
17
16
2
15
1
6
14
13
MS-CAN
7
11
12
MS-CAN
9
10
E97736
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-16
412-01-16

Item
Description
Item
Climate control module

Refer to Component Description: Climate
control module - vehicles with DVD
(page 25)
10

11
12
Left-hand air outlet temperature sensor left-hand center vents
13

center vents
14

footwell
15

footwell
16
Solar sensor
Refer to Component Description: Sun
sensor - vehicles with automatic
temperature control (page 25)
17

26)

Refer to Component Description: Blower
control module - vehicles equipped with
Blower motor
26)
Air flap actuator

flap

flap

vents

vents
2008.50 Kuga 8/2011
Description
G1034947en

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Climate Control
412-01-17
412-01-17

Air conditioning system - vehicles with manual temperature control
HS-CAN
5
MS-CAN
E97576
Item
Description
Item
Description

manual temperature control (page 24)

instrument cluster
High pressure limiting switch
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-18
412-01-18

Item
8
Description
Item
Description
Air conditioning system - vehicles with automatic temperature control
HS-CAN
5
MS-CAN
MS-CAN
E97577
Item
Description
Item
Description


instrument cluster
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-19
412-01-19

Item
Description
Item
Description
High pressure limiting switch
System Operation
Climate control housing
General overview
7
10
11
12
8
6
13
1
2
3
E97261
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-20
412-01-20

Item
Description
Item
Blower motor
26)
Temperature blend door motor
Air distribution flap, demister vents
Air distribution door - center vents
Air distribution door - footwell
10
Air intake door
11
Air duct, demister vents
12
13
Pollen filter
24)
Evaporator assembly
Heat exchanger
Electric booster heater (if equipped)
Description
Air flow - defroster vents
E69659
Item
Description
Warm air
Cold air
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-21
412-01-21

Air flow - center vents
E69660
Item
Description
Warm air
Cold air
2008.50 Kuga 8/2011
G1034947en

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Climate Control
412-01-22
412-01-22

Air flow footwell
E69661
Item
Description
Warm air
Cold air
Climate control
Two options are available:
manual climate control
Air conditioning system with automatic
temperature control (DEATC)
2008.50 Kuga 8/2011
G1034947en

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Climate Control
412-01-23
412-01-23
5
1
2
4
3
10
11
E100819
Item
Description
Item
Description
Condenser
Evaporator Core Orifice Tube
Cooling fans.
Suction accumulator
High - pressure (liquid and warm)
Evaporator assembly
Low - pressure (liquid and cool)
Blower motor
10
Low pressure (gaseous and cold)
11
High pressure (gaseous and hot)
The engine driven refrigerant compressor (2) sucks

in gaseous refrigerant from the suction accumulator
and compresses it. The temperature of the
refrigerant rises to a value between 70 C and 110
C. It passes to the condenser (1) under high
pressure.
At this point heat is drawn from the refrigerant by
the air being forced past the cooling fins. Because
of this heat loss, the refrigerant liquefies and leaves
the condenser.
A fixed orifice tube (6), which separates the
refrigerant at high pressure from that at low
pressure, is located between the condenser and
the evaporator (5). This fixed orifice tube slows
down the flow of the refrigerant from the
2008.50 Kuga 8/2011
compressor, so that pressure builds up in the

condenser.
After passing through the fixed orifice tube the
liquid refrigerant expands in the circuit to the
evaporator, where it becomes gaseous. This
causes heat to be extracted from the air coming
into the vehicle. The air cools down, and excess
moisture contained in it is condensed and is
drained off. The refrigerant coming from the
evaporator flows into the refrigerant accumulator
and is again sucked in by the refrigerant
compressor.
The system is protected by a high-pressure limiting
switch, in order to prevent damage by excessive
pressure (e.g. because of overfilling with
refrigerant). If the pressure exceeds the maximum
G1034947en

TO MODEL INDEX
412-01-24
Climate Control
412-01-24

permitted, the high-pressure switch turns off the
refrigerant compressor.
Pollen filter
The compressor on-off cycle is controlled by the

dual pressure switch depending on the pressure
in the refrigerant accumulator. The dual pressure
switch turns the refrigerant compressor off
permanently if the pressure falls below a permitted
value (e.g. if there is a leak).
E97720
The fresh air flowing into the vehicle through the

air inlet housing passes through a pollen filter which
is located on the left-hand side of the climate
control housing (LHD and RHD) and removes
pollen and dust particles measuring 0.003 mm or
more.
Control assembly, climate control vehicles with manual temperature control

E100826
The special feature of a compressor with variable

swash plate is that the stroke of the pistons can
be varied by means of the variable swash plate.
The swash plate is mounted on a slide rail in the
axial direction.
The piston stroke and thus the delivery rate are
determined by means of the variable obliqueness
of the swash plate.
The obliqueness of the swash plate is dependent
upon the chamber pressure and thus on the
pressure conditions at the top and bottom of the
piston. This is supported by springs in front of and
behind the swash plate.
The chamber pressure is determined by the high
and low pressure applied to the control valve and
by a calibrated orifice bore. If the low pressure is
relatively high, the control valve is opened and the
chamber pressure is reduced.
If the low pressure is relatively low, the control
valve is closed and the chamber pressure is
increased. The force due to the chamber pressure
exerted on the piston bottom, is higher than the
sum of the force due to the low pressure on the
piston top and the spring force.
2008.50 Kuga 8/2011
E97721
In vehicles with manual temperature control, the

heating and air conditioning are operated using
three rotary switches. The air distribution flaps are
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a rod to the control assembly for the climate
control. The temperature control flap is also
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a cable to the control assembly. In addition, the
operating switch for recirculated air mode and the
on/off switch for the air conditioning are located on
the control assembly.
G1034947en

TO MODEL INDEX
412-01-25
Climate Control
412-01-25

Control assembly, climate control vehicles with automatic temperature
control
in this unit. In addition, all heating and air

conditioning functions can be controlled via the
touchscreen. The information exchange takes place
on the mid-speed CAN bus (MS-CAN).
Climate control module - vehicles with DVD

E97722
Vehicles with automatic temperature control have

a control assembly with the following button
operated functions:
Switching the air conditioning system on and
off
Temperature adjustment for the driver's
side/front passenger's side
Switching the windshield defrost function on and
off
Switching the electronic automatic climate
control and the dual mode on and off
Air distribution
Blower Control
Switching off the dual automatic climate control
Recirculated air control
E97724
On vehicles with a DVD navigation system with a

touch screen, the climate control module is
provided as a separate component underneath the
DVD navigation unit. It is actuated via control
buttons or via the navigation touch screen.
Sun sensor - vehicles with automatic

temperature control
Control assembly, climate control vehicles with DVD navigation system with
a touch screen
E97725
For vehicles with automatic temperature control

the sun sensor determines the intensity of the
sunload. The sunload serves as an additional
parameter for determining the blower air
temperature, the air distribution and the blower
speed.
E97723
On vehicles with a DVD navigation system with a

touch screen, the control buttons for the automatic
temperature control (climate control) are integrated
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
412-01-26
Climate Control
412-01-26

E97731
The interior temperature sensor measures the

temperature in the passenger compartment and
thereby also helps to control the pre-selected
interior temperature. This is an NTC resistor.
In order to achieve optimum measurement values,
an integrated blower draws air from the interior into
the in-vehicle temperature sensor.
Blower motor
E98855
On vehicles with electronic automatic temperature

control (EATC), a blower motor with brushes is
used.
Blower control module - vehicles equipped

with automatic temperature control
Ambient temperature sensor
E97726
E98860
The outside-temperature sensor measures the

ambient temperature outside the vehicle. The
resistance, and so the voltage drop at the sensor,
alter depending on the outside-air temperature.
This is an NTC resistor.
On vehicles with electronic automatic temperature

control (EATC) a blower control module is fitted
instead of the conventional blower motor resistor.
This is located in the usual position next to the
blower motor, so that the cooling fins of the module
are cooled by the air flow.
The climate control module regulates the blower
control module via a PWM signal, which in turn
regulates the voltage at the blower motor to
between 3 V and 12.8 V, in an infinitely variable
manner.
The blower control module is fitted with a
temperature monitor which continuously monitors
the internal temperature of the module. If the
temperature rises above 105C, the blower motor
is switched off until the temperature in the module
falls to below 100C.
If the current rises above the value of 26 A 3 A
defined in the blower control module (e.g. high
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
412-01-27
Climate Control
412-01-27

dynamic pressure in blower housing during fast
motorway driving), the current flow through the
blower motor is limited by the blower control
module, until a safe value is reached. If this value
cannot be achieved (e.g. blower motor blocked or
partially seized or dynamic pressure in the blower
housing permanently too high), the value is limited
to 6 A 2 A.
Under normal conditions, the blower motor control
returns to the normal state.
2008.50 Kuga 8/2011
G1034947en

TO MODEL INDEX
Climate Control
412-01-28
412-01-28
Air Conditioning (A/C) Compressor 2.5L Duratec

(147kW/200PS) - VI5(34 626 4)
Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA

Installation).
3.
are sealed.
2. Torque: 20 Nm
3. Torque: 25 Nm
Removal
1
2
2
E112667
Installation
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
2008.50 Kuga 8/2011
G1158270en

TO MODEL INDEX
Climate Control
412-01-29
412-01-29
Air Conditioning (A/C) Compressor to Condenser Discharge Line

Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
2.
5.

Torque: 20 Nm

Torque: 8 Nm
E101236
Installation
E101235


(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
4.
E98183
2008.50 Kuga 8/2011
G1068631en

TO MODEL INDEX
Climate Control
412-01-30
412-01-30
Air Conditioning (A/C) Compressor to Condenser Discharge Line

Materials
Name
Conditioning
Specification
WSH-M1C231-B /
6U7J-M1C231-AA
Removal
2.
5.

are sealed.
Torque: 20 Nm

are sealed.
Torque: 8 Nm
E112730
Installation
E112729


(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
4.
E98183
2008.50 Kuga 8/2011
G1158276en

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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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SECTION 100-00 General Information

DESCRIPTION AND OPERATION

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Lubricants and Greases.....................................................................................................

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DESCRIPTION AND OPERATION

About This Manual

Vehicle LH and RH definition

This manual covers diagnosis and testing and

It is structured into groups and sections, with

A group covers a specific portion of the vehicle.

References to LH (left-hand) and RH

All LH and RH references to the engine are taken

2008.50 Kuga 8/2011

FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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DESCRIPTION AND OPERATION

Powertrain LH and RH definition

Warnings, Cautions and Notes in This

CAUTION: Cautions are used to indicate

If a warning, caution or note only applies to one

How to use Repair Procedures

Important Safety Instructions

Global Authoring Standards (GAS) Repair

The following list details the general policy for the

Anyone who departs from the instructions provided

2008.50 Kuga 8/2011

FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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DESCRIPTION AND OPERATION

Completely coated self-locking bolt

Partially coated self-locking bolt

Self-locking bolt with a locking washer

Self-locking nut with a plastic locking insert

Self-locking nut with thread deformation

Self-locking nut with thread deformation

Self-locking nut with integrated locking ring

All types of seals and gaskets must be

Nuts and bolts with a mechanical locking such

All type of glued exterior trim parts or parts

Specification procedures will only contain technical

If components must be removed or installed in a

2008.50 Kuga 8/2011

FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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DESCRIPTION AND OPERATION

Brown - Components that need to be

Yellow - Components to be set aside only,

Magenta - Electrical connectors and

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